JP5547291B2 - Co-extruded layered candy and gum apparatus and method - Google Patents

Description

  The present invention relates generally to confectionery manufacturing systems and methods, and more particularly to confectionery manufacturing systems and methods for manufacturing multilayer confectionery compositions comprising at least two confectionery composition layers formed from different confectionery compositions.

  Typically, confectionery compositions such as gums or candies are distributed as entirely separate products, or as products that are eaten as substantially separate products. More specifically, some current confectionery products will include a hard candy shell that will encase a separate confectionery composition, such as a gum or chewy toffee-type confectionery. Unfortunately, the user is not given the visual benefit of being offered two separate confectionery compositions at the same time, and the user gets the flavor and sensory benefits of both separate confectionery compositions simultaneously There is nothing.

  The present invention therefore relates to improvements in the technical field of multi-component confectionery compositions.

  Embodiments of the present invention relate to improvements in methods and manufacturing systems for producing confectionery compositions formed from a plurality of different confectionery compositions. The plurality of confectionery compositions are arranged in a plurality of layers to form a multilayer confectionery composition. The different confectionery compositions that form this multilayer confectionery composition differ in at least one characteristic. In some embodiments, these different layers provide an improved consumer experience. The different characteristics between the different confectionery compositions are based on visual, sensory or taste / feel between the various layers to enhance the overall user experience when consuming the multilayer confectionery composition A distinction can be given aesthetically or physically.

  Accordingly, at least two different confectionery compositions that differ from each other in at least one characteristic will be contained in a substantially separate layer in the final multilayer confectionery composition.

  Some methods of forming a multi-layer confectionery composition form a continuous multi-layer rope composed of at least one layer of a first confectionery composition and at least one layer of a second confectionery composition. And coextruding the first confectionery composition with the second confectionery composition, sizing the multilayer rope and cutting the multilayer rope into pieces.

  In some embodiments, the first confectionery composition in the multilayer confectionery composition will typically be a gum composition. The second confectionery composition in the multi-layered confectionery composition will typically be a candy composition, but is not a candy composition in all embodiments. However, it is contemplated that other embodiments may not include any gum composition, and still further embodiments may be formed solely from the gum composition.

  By combining different confectionery compositions, multi-layer confectionery compositions with improved characteristics including various flavor profiles, textures, flavor release characteristics, sensory ingredients, visual appeal etc. can be produced and consumed Can meet the needs of consumers or otherwise provide an enhanced consumer experience. In a preferred embodiment, by providing both a candy layer and a gum layer, the multi-layered confectionery composition can provide an immediate enjoyment of the candy's flavor, but the multi-layered confectionery composition still has a long gum length. Providing a lasting flavor product.

  To that end, in one embodiment, a method of forming a multi-layer confectionery composition comprises a continuous comprising at least one layer of a first confectionery composition and at least one layer of a second confectionery composition. Co-extrusion of the first confectionery composition with the second confectionery composition to form a typical multi-layer rope, and the multi-layer rope to the desired final width and desired final thickness Sizing, cutting the multilayer rope into pieces having the desired final width, desired final thickness and desired final length dimensions, and wrapping the pieces; Grouping the pieces into packing groups and inserting the packing groups into rigid packages.

  In a more particular embodiment, the first confectionery composition is a gum composition. In a further embodiment, the method further comprises pre-extruding the first confectionery composition prior to co-extruding the gum composition. In addition, the method may include preconditioning the first confectionery composition prior to co-extruding the first confectionery composition. Further, the method may include post-conditioning the multilayered rope after the step of co-extruding the first confectionery composition with the second confectionery composition.

  In some embodiments, sizing the multi-layer rope includes stretching the rope by rope sizing, the rope sizing acting on opposite top and bottom surfaces of the multi-layer rope. Passing the multi-layered rope through a plurality of successive counter-rotating roller pairs, the elongation of the rope increases the linear velocity of the multi-layer rope in each pair of counter-rotating rollers. In a more particular embodiment, the extension of the multi-layered rope stretches the rope linearly along its length, reducing the thickness and width of the rope, the thickness and width being the step of rope sizing the rope. Perpendicular to the length and direction of travel between This stretching may be performed by rope sizing performed by a plurality of consecutive counter-rotating roller pairs, where when following a path defined by this rope, the continuous roller pair is , Decrease in size.

  In order to maintain good adhesion between the various layers, in some embodiments, the first confectionery composition and the second confectionery composition have a desired viscosity ratio of 3: 1 or less. More preferably, the first confectionery composition and the second confectionery composition have a desired viscosity ratio of 2: 1 or less. To that end, in some embodiments, the method may particularly require a step of maintaining this viscosity ratio below a desired viscosity ratio.

  This step of maintaining the viscosity ratio may include recycling a portion of the first confectionery composition that has been dispensed from the pre-extruder during the pre-extruding step. Recycling means that the recycled portion of the first confectionery composition exiting the pre-extruder is directly passed to the pre-extruder without any processing of the recycled portion of the first confectionery composition. It may include returning.

  In some embodiments, it is desirable to have a piece size that is strictly tolerated. Some methods may further include the step of homogenizing the first confectionery composition, which includes pre-extruding the first confectionery composition prior to the co-extrusion step. This pre-extruding step involves recycling a portion of the pre-extruded confectionery.

  Since piece size can be important, some methods can sample the average size of the first plurality of pieces, and when this average size is outside a predetermined tolerance range, Including adjusting. This may further include a step of pre-extruding the first confectionery composition prior to the step of co-extruding the first confectionery composition. This pre-extruding step includes reusing the portion of the first confectionery composition that is pre-extruded so that the portion to be reused needs to be pre-extruded more than once. Further, the step of adjusting the processing parameter includes increasing the amount of reuse when the average size is outside a predetermined tolerance range. In some embodiments, the step of adjusting the processing parameter includes the first confectionery by one or more of the pre-extruder or co-extruder when the average size is outside a predetermined tolerance range. Including increasing the amount of work put into the composition. In a further embodiment, the step of adjusting the processing parameter reduces or increases the rate at which the first confectionery composition is fed to the co-extruder when the average size is outside a predetermined tolerance range. Including that.

  In other embodiments, at least one of the first confectionery composition or the second confectionery composition is a chewy candy composition comprising fondant as an ingredient, the fondant being an ingredient in the chewy candy Indistinguishable from the rest of The method may further include the step of substantially crystallizing the chewy candy composition prior to the step of inserting the packing group into the rigid package. This prevents oozing and cold flow of this chewy candy after packing.

  In some embodiments, the co-extruding step includes a first layer, a second layer, and a third layer, the second layer sandwiched between the first layer and the third layer. Extruding a multi-layered rope having three successive layers, wherein the first layer and the third layer are formed from the same confectionery composition. In a preferred embodiment, the first layer and the third layer are formed from a first confectionery composition that is a gum composition, the gum composition during the step of sizing the multi-layer rope. It has a higher viscosity value than the other layer.

  To eliminate tolerance stacking during packaging, in some embodiments, cutting the multi-layered rope into pieces defines the final length of each piece during the cutting step. including.

  In order to prevent the confectionery composition from adhering to processing equipment without eliminating the visual appeal of a separate layer, especially when using chewy candy, a preferred method is to size a multi-layered rope. Prior to the step, a step of applying an adhesion preventing processing aid to the multilayer rope may be included. Furthermore, this anti-sticking processing aid does not give any residue that significantly affects the visual layered characteristics of the multilayer rope. In some embodiments, applying the anti-adhesion processing aid to the multi-layer rope prior to sizing the multi-layer rope includes applying an anti-adhesion processing aid that is mineral oil.

  In some embodiments, after the co-extrusion step, the multi-layer rope is a second confectionery composition sandwiched between a second layer and a third layer formed by the first confectionery composition. A first layer formed by the object, the first layer having a first surface in direct contact with the first surface of the second layer, the first layer The layer has a second surface opposite the first surface that is in direct contact with the first surface of the third layer. The multi-layered rope has a desired final width and a width and thickness greater than the desired final thickness, both width and thickness being substantially perpendicular to each other and the length of the rope.

  In order to prepare the multi-layer rope for cutting and wrapping, in some embodiments, the method further includes conditioning the multi-layer rope after the sizing step.

  In a further embodiment, the method of co-extruding a multilayer confectionery composition having at least one lower viscosity layer sandwiched between two higher viscosity layers is a final piece of the multilayer confectionery composition. Extruding a continuous multi-layer rope of the multi-layer confectionery composition having an initial width and thickness greater than the width and thickness of the And bulk-sizing the multilayer rope, including shrinking both the width and thickness of the multilayer rope.

  In a preferred embodiment, the stretching step includes accelerating the linear velocity of the multilayer rope along the multilayer rope flow path. Further, the step of shrinking both the width and thickness of the multilayer rope may be performed simultaneously with the step of stretching the multilayer rope, or may be the result of the step of stretching the multilayer rope. . The process of stretching and shrinking at the same time can change the dimensions of all of the layers of this multi-layered rope. However, in some embodiments, different layers of the above layers will stretch or shrink at a different rate than other layers of those layers.

  In one preferred embodiment, the initial thickness of each layer is equal, and after the shrinking step, the layer thickness is not equal. In one embodiment, the initial widths of the at least two layers are not equal and there is a first percentage difference between them. After the bulk sizing step, the widths of the at least two layers have a second percentage difference between them that is less than the first percentage difference. In one more specific embodiment, this second percentage difference is less than 5. In an even more specific embodiment, this second percentage difference is less than 0.5%.

  In some embodiments, the layered confectionery need not be performed by a coextrusion process. Accordingly, in one embodiment, a method of forming a piece of a multi-layered confectionery composition includes: a first confectionery composition that forms a first layer of a multi-layered rope; and at least one feature of the first confectionery Forming a multilayer rope comprising a second confectionery composition different from the composition and forming the second layer of the multilayer rope; conditioning the multilayer rope; and Dividing the multilayer rope into individual pieces after the conditioning step, wherein the first layer and the second layer each define a portion of the outer periphery of the cross-section of the multilayer rope. .

  In some methods, the forming step includes co-extruding or laminating the layers of the multilayer rope. In a more particular method, the multilayer rope includes a third layer, and the first layer, the second layer, and the third layer form a portion of the outer periphery of the cross section of the multilayer rope. The method may further include sizing the multi-layered rope prior to the conditioning step. The method may further include sizing the multilayer rope after the conditioning step. In a preferred embodiment, the layers of the multi-layered rope are non-concentric sheets.

  In order to maintain a good piece size and to prevent the multi-layered confectionery from separating between individual layers, in some embodiments, the method includes at least one prior to coextrusion. Maintaining a uniform temperature of the two compositions. One such method differs from the first confectionery composition in at least one aspect and provides a first layer of the multilayer rope, and the first of the multilayer rope. Co-extruding a multi-layer rope comprising a second confectionery composition providing two layers, wherein the temperature of the first confectionery composition is substantially uniform immediately prior to the co-extrusion of the multi-layer rope. Forming a multi-layered confectionery composition comprising:

  In a more specific embodiment, this substantially uniform temperature has a tolerance level of plus or minus 5 degrees Celsius. In a more specific embodiment, this substantially uniform temperature has a tolerance level of plus or minus 3 degrees Celsius. These methods pre-extrude the first confectionery composition prior to the step of co-extrusion of the multilayered rope to increase the temperature uniformity of the first confectionery composition prior to the step of co-extrusion. A process may be further included. The pre-extruding step is such that at least a portion of the first confectionery composition is pre-extruded twice or more in order to increase the temperature uniformity of the first confectionery composition prior to the co-extrusion step. Recycling a portion of the first confectionery composition may be included. At least 25% of the product of this pre-extrusion process may be reused. At least 50% of the product of the pre-extrusion process may be reused. At least 75% of the product of the pre-extrusion process may be reused.

  These methods may further comprise manufacturing the first confectionery composition using a batch manufacturing process, wherein a portion of the first confectionery composition is less than about 2 hours prior to the pre-extrusion step. And a step of storing for longer than about 10 minutes. Alternatively, storing the first confectionery composition for less than about 1 hour prior to the pre-extrusion step.

  When the first confectionery composition is a gum composition, the substantially uniform temperature may be about 50 ° C. in one embodiment. In another embodiment, the substantially uniform temperature of the gum composition is selected from the group consisting of 45, 46, 47, 48, 49, 50, 51, 52, 53, 54 and 55 ° C.

  When the first confectionery composition is a candy composition, the substantially uniform temperature is, in one embodiment, about 35 ° C. In another embodiment, the substantially uniform temperature of the gum composition is selected from the group consisting of about 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, and 40 ° C.

  Some methods of the invention include maintaining a uniform temperature of the at least one composition after the co-extrusion step. One particular embodiment includes a first confectionery composition that provides a first layer of a multilayer rope, and a second layer of the multilayer rope that differs from the first confectionery composition in at least one aspect and A first confectionery composition immediately before the step of bulk sizing the multilayer rope. The temperature of the product includes a method of forming a multi-layered confectionery composition that is a substantially uniform temperature.

  In a more specific embodiment, this substantially uniform temperature has a tolerance level of plus or minus 5 degrees Celsius. In a more specific embodiment, this substantially uniform temperature has a tolerance level of plus or minus 3 degrees Celsius. These methods involve pre-extrusion of the first confectionery composition prior to the step of co-extrusion of the multilayered rope in order to increase the temperature uniformity of the first confectionery composition prior to the step of co-extrusion. You may further include the process to do. This pre-extruding step is performed so that at least a portion of the first confectionery composition is pre-extruded twice or more in order to increase the temperature uniformity of the first confectionery composition prior to the co-extrusion step. Recycling a portion of one confectionery composition may be included. At least 25% of the product of this pre-extrusion process may be reused. At least 50% of the product of the pre-extrusion process may be reused. At least 75% of the product of the pre-extrusion process may be reused.

  These methods may further comprise manufacturing the first confectionery composition using a batch manufacturing process, wherein a portion of the first confectionery composition is less than about 2 hours prior to the pre-extrusion step. And a step of storing for longer than about 10 minutes. Alternatively, storing the first confectionery composition for less than about 1 hour prior to the step of pre-extruding.

  When the first confectionery composition is a gum composition, the substantially uniform temperature may be about 50 ° C. in one embodiment. In another embodiment, the substantially uniform temperature of the gum composition is selected from the group consisting of 45, 46, 47, 48, 49, 50, 51, 52, 53, 54 and 55 ° C.

  When the first confectionery composition is a candy composition, the substantially uniform temperature is, in one embodiment, about 35 ° C. In another embodiment, the substantially uniform temperature of the gum composition is selected from the group consisting of about 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, and 40 ° C.

  In some embodiments, the method includes a desired temperature difference between the various compositions of the confectionery composition prior to co-extrusion into multiple layers. One such method includes forming a multilayer confectionery composition, wherein forming the multilayer confectionery composition includes a first confectionery composition that provides a first layer of a multilayer rope, and Coextruding a multi-layer rope comprising a second confectionery composition that differs from the first confectionery composition in at least one feature and that provides a second layer of the multi-layer rope, the first confectionery comprising The composition has a first temperature just before the co-extrusion step, and the second confectionery composition has a second temperature just before the co-extrusion step, and the first temperature and the second temperature The temperature difference between the temperatures is less than a predetermined temperature difference.

  In one embodiment, the predetermined temperature difference is less than 20 ° C. In a further embodiment, the predetermined temperature difference is less than 15 ° C. In a further embodiment, the predetermined temperature difference is less than 10 ° C. In another embodiment, the predetermined temperature difference is about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 Or 20 ° C.

  Alternatively, the temperature difference between the various confectionery compositions may be maintained just prior to the bulk sizing process. One such method includes forming a multilayer confectionery composition, wherein forming the multilayer confectionery composition includes a first confectionery composition that provides a first layer of a multilayer rope, and Coextruding a multilayer rope comprising a second confectionery composition that differs from the first confectionery composition in at least one feature and provides a second layer of the multilayer rope; Sizing, wherein the first confectionery composition has a first temperature just before the bulk sizing step, and the second confectionery composition has a second temperature just before the bulk sizing step. The temperature difference between the first temperature and the second temperature is equal to or less than a predetermined temperature difference.

  In one embodiment, the predetermined temperature difference is less than 20 ° C. In a further embodiment, the predetermined temperature difference is less than 15 ° C. In a further embodiment, the predetermined temperature difference is less than 10 ° C. In another embodiment, the predetermined temperature difference is about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 Or 20 ° C.

  The method according to the present invention may also include matching the viscosities of various layers, particularly adjacent layers, to provide improved adhesion between layers and sizing of the multilayer composition. In one embodiment, one such method includes a method of forming a multi-layer confectionery composition, the method of forming the multi-layer confectionery composition comprising a first layer that provides a first layer of a multi-layer rope. And co-extruding a multilayered rope comprising a second confectionery composition that differs from the first confectionery composition in at least one aspect and provides a second layer of the multilayered rope. Separating the multilayer rope into individual pieces, wherein the first viscosity of the first confectionery composition is such that the first confectionery composition has a first viscosity prior to the step of coextrusion of the multilayer rope. Consistent with the second viscosity.

  Preferably, the viscosity of the second confectionery composition is about 95% of the viscosity of the first confectionery composition. Alternatively, the viscosity of the second confectionery composition may be about 90% of the viscosity of the first confectionery composition. However, the viscosity of the second confectionery composition is about 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, of the viscosity of the first confectionery composition. Selected from the group consisting of 94 and 95%.

  These methods include the step of pre-extruding the first confectionery composition prior to the step of co-extruding the multi-layered rope to provide the first confectionery composition with a first viscosity within a desired viscosity range. Further, it may be included. This pre-extruding step recycles a portion of the first confectionery composition so that at least a portion of the first confectionery composition is pre-extruded twice or more to increase the uniformity of the first viscosity. Including doing. These methods may further include manufacturing the first confectionery composition using a batch manufacturing process, further including storing a portion of the first confectionery composition for less than about 2 hours. But you can.

  Another method according to the present invention may also include matching the viscosities of the various layers, particularly adjacent layers, to provide improved adhesion between layers and sizing of the multilayer composition. Viscosity is determined prior to bulk sizing. One such method includes a method of forming a multilayer confectionery composition, the method of forming the multilayer confectionery composition comprising a first confectionery composition that provides a first layer of a multilayer rope, and Coextruding a multilayer rope comprising a second confectionery composition that differs from the first confectionery composition in at least one feature and provides a second layer of the multilayer rope; Bulk sizing and dividing the multilayer rope into individual pieces, wherein the first viscosity of the first confectionery composition is the second confectionery prior to bulk sizing the multilayer rope. Consistent with the second viscosity of the composition.

  Preferably, the viscosity of the second confectionery composition is about 95% of the viscosity of the first confectionery composition. Alternatively, the viscosity of the second confectionery composition may be about 90% of the viscosity of the first confectionery composition. However, the viscosity of the second confectionery composition is about 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, of the viscosity of the first confectionery composition. Selected from the group consisting of 94 and 95%.

  These methods include pre-extruding the first confectionery composition prior to co-extruding the multi-layer rope to provide the first confectionery composition with a first viscosity within a desired viscosity range. May further be included. This pre-extruding step recycles a portion of the first confectionery composition so that at least a portion of the first confectionery composition is pre-extruded twice or more to increase the uniformity of the first viscosity. Including doing. These methods may further include manufacturing the first confectionery composition using a batch manufacturing process, further including storing a portion of the first confectionery composition for less than about 2 hours. But you can.

  During processing of the multi-layered confectionery composition, some of the multi-layered confectionery compositions can become salvage, thus preventing this usable waste from being wasted. There is a need. Therefore, one such method according to the present invention includes a method of forming a multi-layer confectionery composition, the method of forming the multi-layer confectionery composition comprising a first method for forming a multi-layer rope. Combining the confectionery composition of claim 1 with a second confectionery composition, wherein the first confectionery composition provides a first layer of a multi-layered rope and the second confectionery composition is in the at least one aspect Different from one confectionery composition and providing a second separate layer of multi-layer rope, dividing the multi-layer rope into individual pieces, a portion of the multi-layer rope comprising a multi-layer rope Recycling a portion of the multi-layered rope so as to pass through a step of combining the first confectionery composition with the second confectionery composition to form a

  One particular embodiment relating to the available waste comprises a first confectionery composition comprising mixing a plurality of ingredients in at least one first mixer to produce a first confectionery composition Producing a second confectionery composition comprising producing a product and mixing a plurality of ingredients in at least one second mixer to produce a second confectionery composition The step of recycling includes adding the portion to be recycled to at least one first mixer and / or at least one second mixer. Preferably, this recycled portion provides up to 20% by weight of the components to be mixed in at least one first mixer and / or at least one second mixer. Even more preferably, the recycled portion provides up to 10% by weight of the components to be mixed in at least one first mixer and / or at least one second mixer. Even more preferably, the recycled portion is 1, 2, 3, 4 or 5% by weight of the components mixed in at least one first mixer and / or at least one second mixer. Give:

  In one embodiment, the first confectionery composition is a gum composition. In one embodiment, the second confectionery composition is a candy composition.

  In one embodiment, the first confectionery composition has a different viscosity than the second confectionery composition, and the step of recycling the multi-layer rope is the first confectionery to which the portion to be recycled is added. The viscosity of the composition or the second confectionery composition is not changed by more than 10% compared to when no recycle is added.

  In one embodiment, the first confectionery composition has a different elasticity than the second confectionery composition, and the recycling step comprises either the first confectionery composition or the first confectionery composition to which the portion to be reused is added. The elasticity of the confectionery composition of 2 is not changed by more than 10% compared to the case where no recycle is added.

  Some methods involve pre-extruding the first confectionery composition using a pre-extruder prior to combining the first confectionery composition with the second confectionery composition to form a multilayered rope. It further includes an extruding step. The step of recycling the multi-layered rope includes adding the recycled portion to the pre-extruder so that at least a portion of the recycled portion is pre-extruded at least twice.

  Some methods may utilize multiple sizing steps to perform bulk sizing and then to perform even more accurate sizing of the multi-layered rope. One such embodiment is the step of combining a first confectionery composition with a second confectionery composition to form a multilayer rope, wherein the first confectionery composition is the first of the multilayer rope. Providing a second layer, the second confectionery composition being different from the first confectionery composition in at least one aspect and providing a second separate layer of the multilayer rope; The step of bulk sizing the multi-layered rope, the step of conditioning the multi-layered rope after the step of bulk sizing, and the first dimension of the multi-layered rope is the desired size Forming a multi-layered confectionery composition comprising a step of finishing-sizing the multi-layered rope after the conditioning step so that it is or very close to the desired dimensions Including how to.

  In one embodiment, this bulk sizing step places the first dimension at 80% of the desired dimension. In a further embodiment, the bulk sizing step places the first dimension at 85% of the desired dimension. In another embodiment, the bulk sizing step places the first dimension at 90% of the desired dimension. In another embodiment, the bulk sizing step places the first dimension at 95% of the desired dimension.

  In one embodiment, this first dimension is within 5% of the desired dimension after the finishing sizing step. In a further embodiment, the first dimension is within 1, 2, 3, or 4% of the desired dimension after the finishing sizing step.

  In one embodiment, bulk sizing and finish sizing are performed by the same type of sizing. In a preferred embodiment, the bulk sizing and finish sizing are rope sizing.

  In order to prevent depletion of the co-extruder or overfeeding the co-extruder, giving the first multi-layer rope with undesirable dimensions or voids, one method according to the present invention is A method of forming a multi-layer confectionery composition comprising a method of forming a confectionery composition, the first confectionery composition providing a first layer of a multi-layer rope, and in at least one aspect, the first confectionery Prior to the steps of co-extruding a multi-layered rope different from the composition and comprising a second confectionery composition that provides a second layer of multi-layered rope using a co-extruder, and co-extruding, Feeding the first confectionery composition to the co-extruder at a desired feed rate.

  In a preferred embodiment, the supply of the first confectionery composition does not vary more than 10% from the desired rate. In a more preferred embodiment, the supply of the first confectionery composition does not vary more than 5% from the desired rate. In one embodiment, the co-extruder comprises an ingredient input that passes when the first confectionery composition is fed, the ingredient input feeding the first confectionery composition to the co-extruder. Having at least one sensor for analyzing the speed to be measured. In one more particular embodiment, the sensor is a load cell that senses the weight of the first confectionery composition amount in the ingredient input.

  In a more specific embodiment, the method further comprises adjusting the rate at which the first component is fed to the component input when this weight is outside the predetermined weight range. This step of adjusting the rate may be performed by slowing down the rate at which the first confectionery composition mass is added to the ingredient input.

  In an even more specific embodiment, the method further comprises pre-extruding the first confectionery composition rope of the first confectionery composition, wherein the first confectionery composition rope is to the ingredient input. And the step of adjusting the speed is carried out by lengthening the supply path along which the first confectionery composition rope moves. The step of lengthening the supply path may include making the supply path meandering.

  In one embodiment, the co-extruder comprises an ingredient input that is passed when the first confectionery composition is fed, and the method further comprises the first confectionery composition when the feed rate is too slow. Adding a separate part to the component input.

  Even in this case, to prevent the multi-layer rope or individual confectionery composition from adhering to the processing equipment, embodiments of the present invention include the use of anti-adhesion processing aids. One embodiment includes a method of forming a multi-layered confectionery composition, the method of forming the multi-layered confectionery composition comprising converting a first confectionery composition to a second confectionery to form a multi-layer rope. Combining with the composition, wherein the first confectionery composition provides a first layer of a multi-layered rope and the second confectionery composition differs from the first confectionery composition in at least one aspect; And providing a second separate layer of the multi-layer rope, each of these first and second layers being visible, applying an anti-adhesive processing aid to the multi-layer rope, and Applying an anti-adhesion processing aid followed by sizing the multi-layered rope, and applying the anti-adhesion processing aid provides a visual distinction between the first layer and the second layer. Decrease by 10% or less.

  In a more specific embodiment, the anti-adhesion processing aid does not substantially provide the effect that the anti-adhesion processing aid obfuscates the visual distinction between the first layer and the second layer. Thus, it is a transparent anti-adhesion processing aid. In one embodiment, the anti-adhesion processing aid is a liquid mineral oil. In another embodiment, the anti-adhesion processing aid is a powder, in which case the anti-adhesion processing aid is applied at a rate less than the normal rate.

  In some embodiments, the various layers of the multi-layered confectionery composition comprise a candy composition. One embodiment is the step of combining a first confectionery composition with a second confectionery composition to form a multilayer rope, wherein the first confectionery composition is a first layer of the multilayer rope. Wherein the second confectionery composition differs from the first confectionery composition in at least one aspect and provides a second separate layer of a multi-layered rope, the second confectionery composition comprising: Includes a method of forming a multi-layered confectionery composition, which is a candy composition.

  In one embodiment, the ingredients forming the candy composition comprise at least 20% by weight of the fondant in an unmixed state, and after mixing of the ingredients, the fondant is a fondant that is a part of the candy composition. Or evenly mixed into the candy composition so that it is not detectable.

  In one embodiment, the ingredients that form the candy composition comprise at least 10% by weight of the fondant of the ingredients in an unmixed state, and after mixing the ingredients, the fondant is a fondant that is among the candy compositions. Or evenly mixed into the candy composition so that it is not detectable.

  In one embodiment, the ingredients that form the candy composition comprise at least 5% by weight of the fondant in an unmixed state, and after mixing of the ingredients, the fondant is a fondant among the candy compositions. Or evenly mixed into the candy composition so that it is not detectable.

  In one embodiment, the method further includes bulk sizing after the combining step. This combining step is performed by coextrusion, where the candy composition is crystallized at least 75% prior to the bulk sizing step.

  In one embodiment, the method further includes bulk sizing after the combining step. This combining step is performed by coextrusion, where the candy composition is crystallized at least 85% prior to the bulk sizing step.

  In one embodiment, the method further includes bulk sizing after the combining step. This combining step is performed by co-extrusion, wherein the candy composition is crystallized at least 90% prior to the bulk sizing step.

  In one embodiment, the method further includes bulk sizing after the combining step. This combining step is performed by coextrusion, where the candy composition is crystallized at least 95% prior to the bulk sizing step.

  In one embodiment, the method further includes bulk sizing after the combining step. This combining step is performed by coextrusion, where the candy composition is crystallized at least 97.5% prior to the bulk sizing step.

  In one embodiment, the method further includes bulk sizing after the combining step. This combining step is performed by coextrusion. The method further includes a conditioning step after the co-extrusion step, wherein the candy composition is at least 85% crystallized after the conditioning step.

  In one embodiment, the method further includes bulk sizing after the combining step. This combining step is performed by coextrusion. The method further includes a conditioning step after the co-extrusion step, wherein the candy composition is at least 90% crystallized after the conditioning step.

  In one embodiment, the method further includes bulk sizing after the combining step. This combining step is performed by coextrusion. The method further includes a conditioning step after the co-extrusion step, wherein the candy composition is at least 95% crystallized after the conditioning step.

  In one embodiment, the method further includes bulk sizing after the combining step. This combining step is performed by coextrusion. The method further includes a conditioning step after the co-extrusion step, wherein the candy composition is at least 97.5% crystallized after the conditioning step.

  Crystallinity can be determined by measuring the particle size of the crystalline particles. These particle sizes may have an average particle size of less than 30 micrometers. Further, these crystalline particles may have an average particle size of about 1 to 25 micrometers.

  In some embodiments, individual pieces may not be individually wrapped and may be dispensed directly into bulk packaging without being wrapped. Thus, the individual pieces may contact each other. However, by incorporating both gum and candy compositions into various multi-layered confectionery compositions, some embodiments allow individual pieces to be stored when stored unwrapped in bulk packaging. Including methods of eliminating or reducing adhesion.

  One method includes a method of forming a multi-layered confectionery composition, the method of forming the multi-layered confectionery composition comprising converting a first confectionery composition to a second confectionery composition to form a multi-layered rope. A first confectionery composition providing a first layer of a multi-layered rope, wherein the second confectionery composition differs from the first confectionery composition in at least one aspect. And providing a second separate layer of the multi-layer rope and cutting the pieces from the multi-layer rope such that each piece has at least one curved surface. Is further formed to have at least one curved surface.

  In one embodiment, the at least one curved surface is formed entirely by the first confectionery composition. In another embodiment, the at least one curved surface is formed by both the first and second confectionery compositions.

  In one embodiment, each individual piece has a substantially constant width and a substantially constant length, and a thickness that varies along the width. The width is smaller than the length. In one embodiment, this thickness is crowned near the center, and the thickness at the two opposite sides defining the width is between the two parallel sides laterally and the two parallel sides. It is smaller than the thickness at the distance from the side. In some embodiments, the thickness is thick near the center, and the thickness at the two opposite sides that define the length is between the two parallel sides laterally and from the two parallel sides. It is smaller than the thickness where there is a gap. In a further embodiment, the thickness is substantially constant in a direction extending substantially perpendicular to the crown.

  In one embodiment, the thickness is a curved profile and varies by at least 5% from its minimum value to its maximum value.

  In one embodiment, s 174-178, this thickness is thick near the center on the opposing surfaces of the individual pieces, with the opposing sides facing away from each other.

  In a further embodiment, each individual piece is cylindrical, each layer is visible, and each layer includes at least one planar surface. This surface will be adjacent to the planar surface of the adjacent layer.

  In one embodiment, the piece includes a third layer. The first layer and the third layer sandwich the second layer between them. The first layer and the second layer are formed from the first confectionery composition. All three layers are visible and form at least part of the circular cross section of the cylindrical piece.

  The above aspects, objects, advantages and embodiments can be used to provide further aspects, objects, advantages and embodiments, and can be combined, ie, used together, as appropriate.

  Other aspects, objects and advantages of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings. Moreover, many of these aspects and embodiments are specified separately. However, these embodiments may be used together as appropriate.

  The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of the invention and, together with the description, serve to explain the principles of the invention.

A simplified illustration of a confectionery processing system for forming a multilayer confectionery composition in conjunction with FIG. 1B is described. A simplified illustration of a confectionery processing system for forming a multilayer confectionery composition in conjunction with FIG. 1A is described. 2 is a simplified flowchart of an exemplary method illustrating processing steps for forming a multi-layered confectionery composition using the system of FIGS. 1A and 1B. 2 is an alternative configuration for forming one of the confectionery compositions within the system of FIGS. 1A and 1B. 1B is a simplified illustration of an exemplary pre-extruder including a recycling configuration for use with the systems of FIGS. 1A and 1B. FIG. 3 is a schematic representation of a portion of a multilayer rope of a representative multilayer confectionery composition formed during the process of FIG. 2 using the system of FIGS. 1A and 1B. 3 is a schematic representation of the final piece of a multi-layered confectionery composition formed using the process of FIG. 2 and the system of FIGS. 1A and 1B. FIG. 7 is a schematic view of a rigid package with a row of pieces of FIG. 6 inserted therein. FIG. 8 is a schematic end view of the rigid package of FIG. 7 illustrating potential problems in packaging resulting from loss of tolerance in processing the multi-layer confectionery composition. 3 is a schematic diagram of a method of cutting a piece of multilayer confectionery composition from a multilayer rope formed during the process of FIG. 2 using the system of FIGS. 1A and 1B. 3 is a schematic diagram of a method of cutting a piece of multilayer confectionery composition from a multilayer rope formed during the process of FIG. 2 using the system of FIGS. 1A and 1B. FIG. 6 is a simplified cross-sectional view of an alternative piece shape for promoting reduced adhesion between pieces that contact each other without packaging material. FIG. 6 is a simplified cross-sectional view of an alternative piece shape for promoting reduced adhesion between pieces that contact each other without wrapping paper. FIG. 6 is a simplified cross-sectional view of an alternative piece shape for promoting reduced adhesion between pieces that contact each other without wrapping paper.

  While the invention will be described in connection with certain preferred embodiments, it is not intended that the invention be limited to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents included within the spirit and scope of the invention as defined by the appended claims.

  Disclosed herein is an improvement in a method and manufacturing system for manufacturing a confectionery composition formed from a plurality of different confectionery compositions. These plurality of confectionery compositions are arranged in a plurality of layers to form a multilayer confectionery composition. The different confectionery compositions that form this multi-layered confectionery composition differ in at least one characteristic and provide an improved consumer experience. The different characteristics between the different confectionery compositions are based on visual, sensory or taste / feel between the various layers to enhance the overall user experience when consuming the multilayer confectionery composition A distinction can be given aesthetically or physically.

  Accordingly, at least two different confectionery compositions that differ from each other in at least one characteristic will be contained in a substantially separate layer in the final multilayer confectionery composition.

  Although not necessarily, the first confectionery composition in the multilayer confectionery composition will typically be a gum composition. The second confectionery composition in the multi-layered confectionery composition will typically be a candy composition, but is not a candy composition in all embodiments. However, it is contemplated that other embodiments may not include any gum composition, and still further embodiments may be formed solely from the gum composition. However, even in this case, the different confectionery compositions will differ in at least one characteristic to provide a new and improved user experience when consuming the multi-layered confectionery composition.

  Unfortunately, various processing challenges can arise when combining confectionery compositions that differ in at least one characteristic into a single confectionery. For example, embodiments of the present invention may provide separation of different layers, formation of a consistent and user-desired piece shape and size, and different layers of those layers adhere to other pieces or to packaging material Concealing or suppressing visual or taste-based benefits of multiple confectionery compositions added to the finished confectionery, as well as avoiding shape or product transitions during or after the manufacturing process It is related to overcoming problems such as prevention.

  By combining different confectionery compositions, multi-layer confectionery compositions with improved characteristics including various flavor profiles, textures, flavor release characteristics, sensory ingredients, visual appeal etc. can be produced and consumed Can meet the needs of consumers or otherwise provide an enhanced consumer experience. In a preferred embodiment, by providing both a candy layer and a gum layer, the multi-layered confectionery composition can provide an immediate enjoyment of the candy's flavor, but the multi-layered confectionery composition still has a long gum length. Providing a lasting flavor product.

  Specific combinations of various multilayer confectionery compositions, and individual confectionery compositions that may be used in various layers of the multilayer confectionery composition formed by the methods and apparatus disclosed herein, International application No. PCT / US09 / 42478, filed on May 1, 2009 and entitled “SUGAR FREE ISOMALT CONCEPTIONY AND METHODS OF MAKING”. International application No. PCT / US09 / 42557 of the title “MULTILAYERED SUGAR FREE ISOMAL CONFECTIONY AND METHODS OF MAKING SAME” (2) International application No. PCT / US2009 / 042468, filed on May 1, 2009 and entitled “SUGAR FREE MANITOLI CONFECTIONIONY AND METHODS OF MAKING SAME”; May 1, 2009 Application, PCT / US09 / 42524, International Application No. PCT / US09 / 42524 of the title of the invention “MULTILAYERED SUGAR FREE MANITOLI CONFITIONER AND METHODS OF MAKING SAME”, PCT / US09 / 42524, May 1, 2009 Name of “SUGAR FREE POLYOL CONFIGURATION AND METHODS OF MAKING SAME” International application No. PCT / US09 / 42495 of “Polyol Confectionary and Method for Producing the Same”; filed on May 1, 2009, entitled “MULTILAYERED SUGAR FREE POLYOL CONFITIONARY AND METHODS OF MAKING SAME” The method and method of manufacture are illustrated in International Application No. PCT / US09 / 42573, the teachings and disclosure of these patent applications are hereby incorporated by reference in their entirety.

  Still further, in some embodiments, the gum composition comprises any of the perfume or sensory elements that may be initially carried with the candy composition when the user chews the multi-layer confectionery composition. Or may be used to absorb some of such perfumes or sensory elements. The candy composition is continuously mixed into or encapsulated in a chewable type part (ie, an elastomeric part or structure) of the multi-layered confectionery composition and consumption of the candy composition Delay.

  Unfortunately, when combining confectionery compositions having different physical properties such as viscoelasticity and thermal properties, the production of individual confectionery compositions, then simply layering the composition, makes such multilayer confectionery compositions It is not the only thing that needs to be considered when forming.

  This becomes even more critical when trying to use standard rigid packaging, such as currently commercially successful rigid packaging, such as cardboard packaging. Because, when it is necessary to consider the various physical properties of the various confectionery compositions of the resulting multi-layered confectionery composition, and sometimes incompatible properties, the tolerancing of the dimensional size of the individual pieces is Because it can be difficult.

General Overview of Processing Steps and Systems The processing steps and machines of exemplary system embodiments of the present invention are described first, followed by more specific features of the processes and systems of more specific embodiments. . In addition, non-limiting and non-exhaustive alternative configurations will be discussed.

  According to an embodiment of the present invention, FIGS. 1A and 1B (collectively referred to as FIG. 1) show a schematic diagram of the processing equipment of the processing system 100 for forming a confectionery composition, and FIG. 2 is a simplified flow chart of the principle processing steps of a method embodiment.

  The confectionery processing system 100 combines processing equipment to perform the 202, 204 steps to form the various confectionery compositions 102, 104 that will be combined to form the multi-layered confectionery composition 120 that forms the final product. In general. The exemplary system 100 is configured to form a multi-layered confectionery composition that includes only two different confectionery compositions.

  Thus, there are two sets of equipment for 202, 204 to initially form confectionery compositions 102, 104. It will be appreciated that more than two different confectionery compositions can be used in this multilayer confectionery composition. In those embodiments, when more than two different confectionery compositions are combined into a multi-layered confectionery composition, typically more than two sets of processing equipment are upstream to form individual confectionery compositions. Will be used during the process.

  However, when there is only a small margin between the different confectionery compositions, some or all of the equipment for forming one of the different confectionery compositions is one of the other different confectionery compositions. Note that it may be used to form parts or all. For example, if the only difference between different compositions is color, and if that color component can be added last, the same equipment may be used to bulk produce a product that is free of colorant. This colorant can then be added to different parts of the bulk product to produce two separate confectionery compositions. However, it will be appreciated that substantially if not all of the same equipment may be used to form the two different confectionery compositions.

  For illustrative purposes, the first confectionery composition 102 is described as a gum composition (hence, also referred to as a gum composition 102). Thus, the first set of confectionery forming equipment, identified entirely at 105, is a gum processing equipment. However, in other embodiments, the first confectionery composition need not be a gum composition.

  In the illustrated embodiment, a typical gum processing facility may be used to form a confectionery composition 202 in the form of a gum structure that forms one or more portions or layers of the multilayer confectionery composition. Good. As shown, this gum processing facility is provided, for example, in the form of a continuous gum mixer 108 (which may also be referred to as a “processing machine”), typically an extruder, and is a continuous one-step process. Used to form a gum composition. However, in another embodiment, such as that illustrated in FIG. 3, this gum processing facility may be provided by a batch mixer configuration 108 '. Representative non-limiting examples of continuous gum mixers, batch gum mixers, or hybrid forms thereof are described in US Provisional Patent Application No. 61 / 016,016, assigned to the present assignee; No. / 036,626; and 61 / 045,764 (the filing date is December 21, 2007; March 14, 2008; April 17, 2008, respectively) The disclosure of provisional patent applications is hereby incorporated by reference in its entirety.

  As illustrated in FIG. 1, the continuous gum mixer 108 receives along its length other gum ingredients such as gum base and flavoring substances, sugars, sweeteners, fillers, various drugs, and the like. A plurality of gum component input sections 110. The gum structure may be any number of a plurality of different types of gum structures, but typically other soluble or other ingredients of the confectionery composition different from the gum composition are gradually added by the consumer. Will include at least an elastomeric portion of the gum that provides continuous or long-term chewability of the multi-layered confectionery composition when consumed or otherwise consumed . The chewable type part provided by this gum composition provides a long-term chewing experience for the user.

  Most typically, however, if the gum composition is not a finished gum, the gum composition will comprise at least a finished gum base and one or more sensory ingredients such as flavorings or sweeteners. The gum composition may not include all of the gum ingredients that would typically be understood as a finished gum. However, other compositions are clearly contemplated and embodiments of the invention disclosed herein are limited to any particular gum composition so long as the gum composition provides long-term chewability. Therefore, it includes any form of elastomer or rubber-like compound known to be used in gum compositions.

  Since the product from the gum mixer 108 will often be output in a non-uniform flow of material having a non-uniform cross-section, the product will generally not have a uniform shape, Or it may be non-uniform. The same is true for the product of the batch mixer configuration 108 'as illustrated in FIG. This is because the product does not have a consistent cross-section and is generally shaped non-uniformly. Alternatively, particularly when using a batch mixing configuration, the resulting gum composition 102 may have inconsistent, shape-related properties (such as a temperature profile), or even non-uniform mixing of ingredients. May also have.

  After forming the gum composition 102, the process includes pre-extruding 206 the gum composition 102. Accordingly, the product of the gum mixer, ie, the continuous gum processor 108, is then fed to the pre-extruder 112.

  When a batch mixing system 108 'is used, the entire bulk gum composition is typically completed at once. However, if no further processing is performed on the gum composition 102 prior to being added to the co-extruder 116 during the 208 step of co-extrusion and formed into a multi-layered confectionery composition, the first The portion of the gum composition 102 used in the process will be at a temperature different from the temperature of the portion of the gum composition 102 that is stored waiting to be processed into a multi-layer confectionery composition. Undesirable process variations can be introduced.

  In one embodiment, the pre-extruder 112 produces one or more ropes of the gum composition 102 that are substantially uniform in physical properties such as viscoelasticity and temperature. Each individual rope dispensed from the pre-extruder 112 will have a substantially constant cross-section for a more uniform supply of downstream processing equipment, such as the co-extruder 116.

  As illustrated in FIG. 4, the pre-extruder 112 is such that at least a portion of the gum composition 102 must pass through the pre-extruder 112 multiple times prior to any further downstream processing. A recycle configuration 114 or a pump around arrangement may be included that returns a predetermined portion of the gum composition (indicated by reference numeral 102 ′ in FIG. 4) to the beginning of the pre-extruder 112.

  This step 210 of reusing the portion 102 ′ of the gum composition 102 facilitates increased consistency in the portion of the gum composition 102 that is allowed to move downstream to further processing equipment. Further increasing the work being added to 102. For example, but not limited to, the reuse configuration 114 may provide a more uniform temperature and increased mixing of the gum composition 102 or a more uniform to avoid variations in the physical properties of the gum composition 102, particularly viscoelasticity. Can be used to provide mixing. This provides a significant advantage in maintaining accurate tolerances on the size of the pieces of the multi-layered confectionery composition produced by the processing system 100. In addition, because the gum composition 102 will be formed into one or more layers adhered to another gum composition, the uniformity of physical properties is consistent and predictable of the different layers. Promotes adhesion.

  For example, it may be desirable to have a substantially uniform gum composition 102 temperature just prior to the coextrusion step so that a consistent extrusion profile is provided. In some embodiments, it may be desirable to have a 5 ° C. or less deviation from the desired temperature. More preferably, it is desired to have a deviation of 3 ° C. or less from the desired temperature. Even more preferably, it is desired to have a deviation of 1 ° C. or less from the desired temperature.

  When the confectionery composition is a gum composition, this uniform temperature is referred to as about 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55 ° C and / or a range therebetween. The desired temperature is preferably about 48-52 ° C.

  Uniformity in the temperature of the candy composition 104 is also desired. This uniform temperature is the desired temperature of about 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40 ° C. and / or a range therebetween, but preferably about 33 to 37 ° C.

  To further promote temperature uniformity of the gum composition prior to co-extrusion step 208, the confectionery composition is left for more than 2 hours prior to being pre-extruded. It is preferably prevented from being stored (ie stored). More preferably, the confectionery composition is prevented from being left for more than 1 hour prior to being pre-extruded. Even more preferably, the confectionery composition is prevented from being left for more than 30 minutes prior to being pre-extruded.

  Since the pre-extruder 112 also forms the gum composition 102 into a rope having a substantially uniform cross section, the 206 step of pre-extruding the gum composition 102 also conditions the rope going downstream for further processing. To make it easier. More specifically, in one embodiment, a preconditioning station shown in the form of a preconditioning tunnel 118 is provided, as illustrated in FIG.

  The preconditioning tunnel 118 is for the 212 step of conditioning the gum composition 102 prior to being combined downstream with the second confectionery composition 104 and again, prior to being processed by the co-extruder 116. In order to promote consistency of the gum composition 102.

  The preconditioning tunnel 118 may be a single pass cooling tunnel. However, in another embodiment and as shown, preconditioning tunnel 118 is a multi-pass conditioning tunnel that may include any number of passes. However, in a still further embodiment, this multi-pass conditioning tunnel provides 3-15 passes through the conditioning tunnel.

  Rather than a fixed number of passes, the preconditioning tunnel 118 was filed on Jan. 12, 2009 and is co-pending US patent application Ser. No. 12 / 352,110 assigned to the assignee of the present application. And the disclosure of which is incorporated herein by reference) may also comprise a loafing and conditioning system. This loafing-conditioning system can be located downstream of the pre-extruder 112 or can replace both the pre-extruder 112 and the pre-conditioning tunnel 118 as illustrated in FIG. Like.

  In any case, the product of the gum processing facility 105 should be consistent in composition, viscoelasticity, and physical properties for proper downstream processing, particularly but not limited to processing in the co-extruder 116. is there.

  The product of the preconditioning tunnel 118 or other conditioning system is then processed into a multilayer confectionary illustrated in the form of a co-extruder 116 for further processing and formation into a co-extruded multilayer confectionery composition. Provided and supplied to the forming device. Although the embodiment of FIG. 1 is illustrated with a conditioning system 118, this conditioning system is optional, and other embodiments may not include the conditioning system 118 prior to the co-extruder 116.

  Prior to discussing the operation of co-extruder 116, the 204 parallel steps of forming second confectionery composition 104 are discussed in connection with a second set of confectionery processing facilities. In the illustrated embodiment of FIG. 1, the second set of confectionery composition processing equipment is indicated generally by the reference numeral 109. This processing equipment 109 is used for the 204 step of forming the second confectionery composition 104 to be added to the multilayer confectionery composition. To discuss the illustrated example, the second confectionery composition 104 is discussed as a chewy candy composition. Therefore, the second confectionery composition 104 may be referred to as a chewy candy 104. However, as previously described, the second confectionery composition 104 is not so limited and could be a second gum composition or other confectionery composition. If the second confectionery composition 104 is a second gum composition, the second confectionery composition 104 uses processing equipment of substantially the same type as previously described with respect to the processing equipment 105. It would be typical.

  In this example, the 204 step of forming the chewy candy composition 104 uses a batch system. Accordingly, the confectionery processing facility 109 is illustrated as a batch system comprising a batch mixing arrangement 111. Processing of the second confectionery composition 104 is a typical candy process that includes cooking the candy composition followed by standard pulling of the chewy candy. This process includes several cooking and pulling procedures to form a chewy candy composition.

  When the chewy candy 104 is properly processed, it is transferred from the batch mixing facility to a further pre-extruder 113. The step 213 of pre-extruding the second confectionery composition 104 using the pre-extruder 113 processes the batch of chewy candy 104 again to provide the chewy candy 104 with more consistent physical properties. This is because the batch of chewy candy 104 is then added to the co-extruder 116. Again, it is desirable to have consistency in temperature, composition, and / or viscoelasticity for the chewy candy 104.

  After roughly manufacturing the confectionery composition and preparing the confectionery composition for the formation of a multi-layered confectionery composition, the process coextrudes the confectionery composition using the co-extruder 116. 208 steps are included. By using the co-extruder 116, the multilayer confectionery composition will initially be in the form of a continuous multilayer rope 120. Although shown schematically in FIG. 1A as a single layer rope, a more detailed illustration of the multilayer rope 120 is shown in FIG. 5 (the embodiment of FIG. 5 will be described in detail later). 3 layers as shown).

  As illustrated in FIG. 1A, the co-extruder 116 has a pair of feed or storage towers 122, 124 that serve as inputs for feeding a variety of different confectionery compositions. More specifically, the storage tower 122 receives the first confectionery composition 102. The storage tower 124 receives the second confectionery composition 104. However, in other embodiments, such as when more than two confectionery compositions are combined to form a multi-layered confectionery composition, the co-extruder 116 has more storage or supply towers, ie, various confectionery compositions. One for each of.

  In some embodiments, a feed tower or storage tower is not required for each layer of the multilayer confectionery composition. In some examples, one feed tower or storage tower may receive a confectionery composition that is used for multiple layers of a multi-layered confectionery composition. For example, the same gum composition may be used to form two layers with different candy layers in between (see, eg, FIG. 5). Accordingly, the same gum composition 102 that forms multiple layers of the multi-layered rope 120 is operably flowing through the co-extruder 116 to form two separate layers. This occurs, for example, with reference to FIG. 5 where layers 121 and 125 are formed from the first confectionery composition 102 and the intermediate layer 123 is formed from the second confectionery composition 104.

  As illustrated in FIG. 5, the layer 121 has a first surface that is in direct contact with the first surface of the layer 123. Similarly, layer 125 has a first surface in direct contact with the second surface of layer 123 opposite the surface in contact with layer 121. In the illustrated embodiment, each layer is considered a non-concentric sheet.

  In addition, when one feed port, i.e. a storage tower, is used to feed one confectionery composition to the co-extruder 116, but not for multiple layers, at the die end of the co-extruder. The pressure is preferably substantially uniform for each of the layers formed by one confectionery composition 102. This uniform pressure prevents uneven product from the co-extruder 116 for two different layers. This is especially true when multiple layers have substantially the same dimensions. When the layers have the same size and are exposed to different pressures, one layer will be extruded at a faster rate than the others, causing deformation in the multi-layer rope 120, which deformation is It can appear in the form of poor adhesion between the various layers of the confectionery composition or a non-uniform profile of the multi-layer rope 120. Alternatively, if different pressures are applied to the different layers, generally voids may be formed in the multi-layer rope 120.

  The confectionery composition inputs to the various storage towers 122, 124, ie, the co-extruder 116, may be offset from one another in the axial direction, in the vertical direction, in the lateral direction. In one embodiment, as previously described, the second confectionery composition 104 forms an intermediate layer of the multilayer confectionery composition. In the illustrated embodiment, the storage towers 122, 124 are offset axially along the co-extruder 116. However, the feed tower 124 may be offset laterally from the flow path defined by the multilayer rope 120 exiting the co-extruder 116. In this configuration, the second confectionery composition must be supplied from the side of the co-extruder at an oblique angle with respect to this flow path and bend in the direction of its movement within the co-extruder 116. In yet another embodiment, the various inputs to the co-extruder 116 may be vertically offset from each other, so that the various inputs are typically the same axial direction along the co-extruder. In position but at different vertical heights are fed to the co-extruder 116.

  The co-extruder 116 typically has a substantially separate flow path through the co-extruder 116 for each of the different confectionery compositions 102, 104 prior to passing through the extruder die. Composed. However, all that is required is that each confectionery composition 102, 104 has a uniaxial configuration. In other words, each layer need not have its own screw configuration to move the confectionery compositions 102, 104 through the co-extruder 116. However, when a single confectionery composition is used for multiple layers, each layer can have its own screw configuration for independently moving that portion of the confectionery composition through the co-extruder 116. That is contemplated. Note that the screw configuration need not be uniaxial, but can be multiple screws, such as a co-rotating or counter-rotating biaxial configuration. To be a separate screw configuration, the screw configuration does not cause its action to add any significant addition to moving different ones of the confectionery compositions through the co-extruder 116. In addition, there must be some separation from other screw configurations.

  Typically, as the multilayer rope 120 exits the co-extruder die, the dimensions of the multilayer rope 120 are significantly greater than the final dimensions of the individual pieces of the multilayer confectionery composition. In order to significantly reduce the force and energy required to push the different layers of the product through the corresponding dies of the co-extruder 116, the multi-layer rope 120 is typically sized larger than the desired final dimension. To be. The large co-extruded multilayer rope 120 can then be sized using a process that is more efficient and requires less energy. Since the end product is typically a plank / board gum that is a generally rectangular piece, a multi-layered rope will typically have a generally rectangular cross-sectional profile.

  Since the multi-layer rope 120 is a continuous rope, it is understood that the dimension along the path of travel (ie, the length L of the multi-layer rope 120 as illustrated in FIG. 5) is virtually infinite. I want. Furthermore, the size of the multi-layered rope coming out of the co-extruder can vary depending on the downstream packaging equipment. If the cut-and-wrap system based on a typical cut-and-wrap machine is downstream from the co-extruder to form individual pieces of multi-layered confectionery, the width and height dimensions May be significantly smaller than if a rolling-scoring system based on a typical rolling-and-scoring machine is downstream of the co-extruder 116.

  For example, if a cutting-packaging system where the pieces are cut directly from the multi-layer rope 120 and then wrapped and packed is used to form a piece of multi-layer confectionery composition, see FIG. When the multilayer rope 120 exits the co-extruder 116, the initial width W of the multilayer rope 120 may be about 20 mm to about 50 mm. More preferably, when the multi-layer rope exits the co-extruder 116, the width W is from about 25 mm to about 40 mm. Even more preferably, the width W of the co-extruded multilayer rope is about 27 mm to 33 mm. These dimensions are such that the width W of the multi-layered rope 120 gives the final width FW of the finished piece 146 of the multi-layered confectionery composition that has gone through a downstream sizing step, as illustrated in FIG. ,used. Furthermore, these dimensions are used with a desired final width FW of the finished piece of about 10 mm to 13 mm.

  However, if the width W of the multi-layer rope 120 provides the final length FL of the finished piece 146 of the multi-layer confectionery composition, a different width W dimension value when exiting the co-extruder 116 may be desired. is there. More specifically, when the multi-layer rope 120 exits the co-extruder 116, the width W of the multi-layer rope 120 may be between about 50 mm and about 150 mm. More preferably, when the multi-layer rope exits the co-extruder 116, the width W is about 60 mm to about 120 mm. Even more preferably, the width W of the co-extruded multilayer rope is between about 70 mm and 100 mm. These dimensions are used when the width W of the multilayer rope 120 gives the final length FL of the finished piece 146 of the multilayer confectionery composition, as illustrated in FIG. In addition, these dimensions are envisioned to be used to form a piece 146 having a desired final length FL of about 30 mm to 40 mm.

  As the multilayer rope 120 exits the co-extruder 116, the initial thickness T of the multilayer rope 120 may be between about 10 mm and about 40 mm. More preferably, when the multi-layer rope exits the co-extruder 116, the thickness T is about 15 mm to about 30 mm. Even more preferably, the co-extruded multilayer rope 120 has a thickness T of about 21 mm to 27 mm. These dimensions are such that the thickness の of the multi-layered rope 120 provides the final thickness FT (see FIG. 6) of the finished piece 146 of the multi-layered confectionery composition, as illustrated in FIG. Used when it comes to. Typically, when forming a multi-layered confectionery composition, the thickness T will be used as the final thickness FT. These thickness values are used when the desired final thickness FT of the piece is about 2-7 mm.

  Alternatively, if the multi-layered rope 120 is not formed directly into individual pieces and the downstream packaging process includes conventional rolling and scoring that is then wrapped, the multi-layered rope 120 may vary widely in width W and thickness. Will have a T dimension. In this configuration, the co-extruder orifice would be about 1 inch x 18 inches (about 2.54 cm x about 45.7 cm) to fit a standard rolling-scoring machine. However, when using multi-layered rope rolling and scoring, the multi-layered rope 120 is a standard rolling and scoring operation to reduce the thickness to the desired final thickness FL of about 2 mm to 7 mm. You may not be able to withstand greater compressive forces.

  For example, if too much compressive force is applied to the multi-layered rope 120, one of the layers may be susceptible to that compressive force, resulting in unwanted lateral oozing of material. . More specifically, if the intermediate layer is a chewy candy that will typically have a lower viscosity than the outer gum layer, the compression of the multi-layer rope will reduce the thickness of all layers of the multi-layer rope. Rather than uniform compression, lateral oozing of the intermediate chewy candy layer can occur. Thus, the actual thickness as it exits the co-extruder can be reduced to less than 1 inch, so that the thickness T of the multi-layer rope 120 is reduced to the desired final thickness. The amount of rolling required to reduce to FT may be reduced.

  It should be noted that the optimal rope width W and thickness T dimensions may vary depending on the actual confectionery composition being matched in the multi-layer rope 120. More specifically, the rope size may be adjusted to the specific physical properties of the confectionery composition, as well as their ability and characteristics regarding bulk sizing.

  When the multilayer rope 120 is being extruded from the co-extruder 116, the multilayer rope 120 is passed through a pair of adhesive rollers 128, 130. Adhesive rollers 128, 130 improve the adhesion between the multiple layers by pressing the multiple layers immediately downstream of co-extruder 116. This added process reduces the occurrence of separation of those multiple layers.

  The multi-layered rope 120 is then passed through a bulk-sizer for the bulk of the multi-layered rope 120, ie, the multiple, sizing 214 process. The bulk sizing 214 step, prior to forming the individual pieces, causes the large multi-layer rope 120 to become a smaller rope having dimensions that are approximately the desired final width FW and final thickness FT of the multi-layer rope. It is a forming process that moves on. In the illustrated embodiment, the bulk sizer is in the form of a multi-roller rope sizer 134. In one embodiment, the rope sizer 134 has a width W and / or thickness T exiting the rope sizer 134 that is preferably at least 75% of the corresponding final dimension, more preferably 85% of the corresponding final dimension, and even more. The multilayer rope 120 will be sized so that it is preferably 95%. When using cutting-wrapping, the rope sizer 134 will preferably make the rope into the two final dimensions of the piece (i.e., thickness and width or length), whereas rolling- If scoring is used, the rope sizer 134 may make the rope one final dimension (ie, thickness).

  The rope sizer 134 comprises a plurality of consecutive roller pairs that progressively reduce the size of the multi-layered rope 120. Rope sizer 134 is schematically illustrated as comprising four pairs 135, 137, 139, 141 sizing rollers. However, other embodiments may have more or fewer pairs of sizing rollers. In the preferred embodiment, the rope sizer 124 is a seven stage sizer having seven roller pairs for continuously reducing the size of the multi-layered rope 120.

  Unlike a standard rolling-scoring roller, the rope sizer 134 operates to extend the multilayered rope 120 linearly along its flow path (ie, length L), which at the same time A lateral contraction of the multilayer rope 120 along both the width W and the thickness Τ of the multilayer rope 120 occurs. This stretching is effected by continuously accelerating the multilayer rope 120 as it passes through the continuous roller pair. Each sizing roller pair 135, 137, 139, 141 operates at a higher linear velocity along the flow path, so that each roller pair is effectively “deficient” in material, so each set of rollers 135, 137, 139, 141 “pull” the multi-layer rope 120 and cause a three-dimensional extension of the multi-layer rope 120 (one positive extension and two negative extensions (ie, contractions)).

  In general, the rope sizer 134 does not provide a significant externally applied compressive force, for example along the thickness direction, such as that provided by a typical bulk sizing roller used in gum sizing, and is therefore particularly thick. When viewed from the side, it is a gentle bulksizer. This gentle action is provided by the Poisson effect due to the linear extension of the multi-layered rope 120 along the length of the flow path, which causes contraction along the thickness and width directions. In other words, the rope sizer 134 uses the transverse shrinkage strain to this elongation strain in the direction of the stretching force to cause shrinkage in the thickness T and width W directions.

  All of these rollers may have the same radial size and only operate at different angular velocities, or have various radial sizes and operate at the same or even different angular velocities, as desired. Note that this may result in a three-dimensional extension. Furthermore, it is not necessary that both rollers of a given roller pair have the same dimensions.

  To facilitate sizing of the multi-layer rope 120 (also referred to herein as multi-layer confectionery composition 120) while avoiding deformation of the layered configuration, i.e., gaps or voids in the various layers of those layers It is desirable to match the viscoelasticity of the confectionery composition well during the bulk sizing process, particularly when using the rope sizer 134, to avoid the formation of slag or the lateral oozing of the corresponding layer . When the properties of the confectionery compositions 102, 104 are significantly out of agreement, the method of the present invention allows the method of the present confectionery composition to match the desired properties of the confectionery compositions 102, 104. Including adjusting one or more processes. Accordingly, modifications to the processing of the multilayer confectionery composition can affect only one, multiple, or all of the confectionery compositions that are combined to form the multilayer confectionery composition 120.

  For example, if the intermediate layer has a viscosity or elasticity that is significantly different from the outer layer during the bulk sizing operation, the stretch effect will not be felt evenly or even proportionally to each layer. Thus, when the outer layer is engaged by the upper and lower rollers of a pair of rollers, this load will not be properly transmitted through the inner layer. For example, if the shrinkage in the width W direction is not transmitted to the intermediate layer, the multilayer rope will no longer remain substantially rectangular in cross section. This is because the intermediate layer will remain in its pre-stretched dimensions, whereas the outer layer will be reduced in size.

  Similarly, if the middle layer has a different elasticity than the outer layer, problems such as the failure of individual layers can result in malfunction of downstream operations or discontinuous parts within a given layer. There is. For example, if the intermediate layer is less resilient than the outer layer, the outer layer can be stretched along the length by a desired amount, while the intermediate layer cannot be stretched by a corresponding amount, Eventually it will break. In addition, this more elastic layer may shrink more in the width direction than the other layers, causing non-uniform shrinkage and causing these layers to shift in the width W direction. Can happen. In some embodiments, this may actually be desired if it is desired to have a shape that is not a prism, ie, a shape with partially rounded sides, as described in more detail below. .

  In order to promote uniform bulk sizing or sizing in general, it is desirable that a given layer has a uniform temperature just prior to the bulk sizing step. This uniform temperature will promote uniform viscoelasticity of a given layer.

  For example, it may be desirable to have a substantially uniform gum composition 102 temperature just prior to the bulk sizing step. In some embodiments, it may be desirable to have a 5 ° C. or less deviation from the desired temperature. More preferably, it is desired to have a deviation of 3 ° C. or less from the desired temperature. Even more preferably, it is desired to have a deviation of 1 ° C. or less from the desired temperature.

  When the confectionery composition is a gum composition, this uniform temperature is referred to as about 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55 ° C and / or a range therebetween. The desired temperature is preferably about 48-52 ° C.

  Uniformity in the temperature of the candy composition 104 is also desired. This uniform temperature is the desired temperature of about 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40 ° C. and / or a range therebetween, but preferably about 33 to 37 ° C.

  Although not immediately before the bulk sizing step, the recycling step is a confectionery both prior to the co-extrusion step and after the co-extrusion step and prior to the bulk sizing step. It can be used to maintain a uniform temperature of the compositions 102,104.

  In addition, if one layer has a different viscosity than another layer, the roller pair will only compress the lower viscosity layer and obtain the desired shrinkage rather than the lower viscosity layer. There is a possibility of oozing out of the layer. For example, if the outer layer is a viscous gum composition and the inner layer has a low viscosity, when the multilayer rope passes through a given roller pair, the change in thickness T is compressed into the multilayer rope. Can cause force, which causes the less viscous material in the middle to exude laterally outward while the more viscous outer gum layer remains substantially the same thickness. Unfortunately, as described above, the width W of the multi-layered rope 120 decreases as the multi-layered rope 120 passes the roller pair due to linear stretching. Thus, if the intermediate layer does not shrink as well, or worse, oozes out, thereby increasing the width of that particular layer, the desired cross section of the multi-layered rope 120 is lost. Furthermore, if the intermediate layer oozes out beyond the outer protective gum composition layer, this intermediate layer causes undesirable interference with various downstream equipment, and debris and material build up on the intermediate layer. May cause you to do. Again, although typically not desired, some embodiments may facilitate this orientation to give the desired piece shape.

  In one embodiment, if a less than equivalent shrinkage occurs for a material that is less viscous than a higher viscosity material, the lower viscosity layer is slightly less than the width of the higher viscosity layer. It may be extruded with a small width.

  When the different layers consist of a gum composition and a candy composition, it may be desirable to have a predetermined temperature difference between these different candy compositions. This is especially true when the viscoelasticity of the different candy compositions is similar to (ie consistent with) the given temperature difference between the different candy compositions. This is understandable, as typically the temperature of the gum or candy composition increases, the viscosity decreases and the elasticity increases. Thus, it is also desirable that there is a similar temperature change for the confectionery composition 104 as one temperature increases, ie for the confectionery composition 102. In other words, it is desirable to maintain some temperature difference between them.

  In some embodiments of the method according to the present invention, especially when the different confectionery compositions are candy and gum compositions, about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12, 13, 14, 15, 16, 17, 18, 19, and 20 ° C. and / or a temperature difference in the range between them may be desirable. These temperature differences may be desired just before the coextrusion process or just before bulk sizing, or both.

  In order to minimize and / or prevent the multi-layered rope 120 from adhering to the rope sizer rollers 135, 137, 139, 141, the process increases the amount of anti-adhesive processing aid 143 prior to the sizing operation. 216 process provided to the outer side of the layered rope 120 is included. This anti-adhesion processing aid can also be called an anti-adhesion agent or a lubricant. Unlike standard gum anti-fouling processing aids, for example, powders such as talc and mannitol, to name but non-limiting examples, Applicants believe that anti-fouling processing aids 243 are substantially transparent. Clarified that is preferable. Therefore, it is preferred to use oil or fat in liquid form rather than typical powders. Applicants have shown that the use of the powders described above will reduce the visual appearance of the multi-layered confectionery composition or otherwise adversely affect the visual appearance. As noted above, one of the significant advantages of the multi-layered confectionery composition is, in some embodiments, an improved visual appeal or experience that is brought to the consumer from a separate layer. Therefore, the powdery, typically white, residue typically left behind by standard powder anti-sticking agents is highly undesirable. However, it should be noted that not all embodiments of the present invention must utilize these non-powdered or oil / fat based anti-stick processing aids 143. This is because a multi-layered confectionery composition can have many other advantages besides just a layered visual appeal.

  In one embodiment, the anti-adhesion processing aid is light oil. However, other anti-adhesion processing aids that are compatible with the outer layer of the multi-layered rope 120, typically a gum composition, may be used. Preferably, any alternative anti-stick processing aids do not interfere with the visual appeal of the finished piece layered configuration.

  The anti-adhesion processing aid 143 may be applied by a continuous drip system 145. This continuous dripping system may provide a single application of the anti-adhesion processing aid upstream of all the rollers 135, 137, 139, 141 of the rope sizer 134. Alternatively, the system may intermittently apply anti-adhesion processing aids between individual pairs 135, 137, 139, 141 of rope sizer rollers. When applying the anti-adhesion processing aid 143 between the roller pairs, the anti-adhesion processing aid 143 may be applied before each roller pair 135, 137, 139, 141, or the roller pair 135, 137. 139, 141 may be given before only some but not all of them.

  Furthermore, this adhesion prevention processing aid need not be applied directly to the multilayered rope 120. Alternatively, anti-adhesion processing aids may be applied directly to the individual rollers 135, 137, 139, 141 of the rope sizer 134.

  After the multilayer rope 120 is bulk sized 214 by passing the rope sizer 134, the multilayer rope 120 is conditioned 218. Thus, the multi-layered rope 120 is passed through a conditioner in the form of a conditioning tunnel 136 (also called a cooling tunnel). Conditioning tunnel 136 is illustrated as a multi-pass conditioning tunnel with temperature and / or humidity control. In one embodiment, conditioning tunnel 136 is a nine-pass conditioning tunnel, but other numbers of passes can be used while remaining within the scope of the present invention. Conditioning tunnel 136 will condition the multi-layered confectionery composition so that the multi-layered confectionery composition is ready for packaging. More specifically, the conditioning tunnel 136 reduces the temperature and establishes or maintains the desired moisture content so that the multi-layered confectionery composition has the desired viscoelasticity to facilitate downstream cutting. become. Typically, this results in increased stiffness and reduced tack or tack, preventing product deformation (ie, bending or poor cutting) or product sticking to downstream cutting devices. This conditioning may be particularly beneficial to help prevent any oozing of any intermediate layer that may have a lower viscosity value than the outer layer.

  For example, in some embodiments, the viscosity of one layer is 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93 of the viscosity value of another layer. , 94, and 95%, and / or ranges between them. Preferably, the difference is less than 5.

  As the multi-layer rope 120 moves from one conveyor to the next (ie, vertically downward), the multi-layer rope 120 extends along the flow path, ie, its length L, and at the same time the width W and thickness. It will shrink along T. In order to prevent bow-tying of the multi-layer rope 120 as the multi-layer rope 120 passes from one level of the multi-pass cooling tunnel 136 to another level, each successive in the conditioning tunnel 136. A simple conveyor has a slightly higher linear conveying speed than a conveyor in front of itself. In some embodiments, the multi-layer rope 120 may increase in linear velocity by about 2% to 15% from when the multi-layer rope 120 enters the conditioning tunnel 136 to when the multi-layer rope 120 exits the conditioning tunnel. . The linear velocity along the flow path will more typically increase from about 4% to 12%, and even more typically from about 6% to about 10%.

  As the multi-layered rope 120 extends along its length L, the rope 120 will also contract along its width W and its thickness T.

  In addition, as the temperature and / or moisture of the multi-layer rope is lowered, the rope 120 will also contract due to the thermal expansion / contraction principle.

  After the conditioning 218 step, the multi-layered rope 120 is further sized again during the 220 step of pre-sizing. Thus, downstream from the conditioning tunnel 136, the pre-sizer 140 performs the finish sizing of the multi-layered rope 120 prior to being formed into individual pieces. In a preferred embodiment, the presizer 140 is a rope sizer that is substantially similar to the rope sizer 134. Thus, this presser generally operates on the rationale of stretching the multi-layered rope 120 to cause contraction in both the width W and thickness T directions. However, the presser has a smaller number of roller pairs since less formation is required. The presizer 140 substantially finishes both the width W and the thickness wrinkles of the multilayer rope 120. Preferably, the presser 140 reduces either the width W or the thickness T by 0.5 mm or less, more preferably 0.2 mm or less. For a limited amount of sizing, a compression roller configuration may be employed as well. In addition, the reduced temperature and increased conditioning time place the multi-layered rope 120 in a better condition for reacting to the compressive forces of other types of sizing operations.

  Presizer 140 preferably has a desired final dimension value of either 95, 96, 97, 98, 99, 99.5 and / or these desired final width FW or final length FL of individual pieces 146. It is preferable to obtain a width W that is in the range between.

  Avoid sticking the multilayer rope 120 to the presizer 140. The system will typically include a further continuous drip system 147 for applying 222 additional anti-adhesion processing aid 149 between the presizer 140 and the multi-layered rope 120. Again, it is preferred that this anti-adhesion processing aid 149 does not impair the visibility of multiple layers of the final product. Typically, this anti-stick processing aid 149 is similar to or the same as the anti-stick processing aid 143 used during rope sizing.

  In addition, during this step, the anti-adhesion processing aid may be applied directly to the sides of the multi-layer rope 120. In the illustrated embodiment, the processing equipment is a pair of so-called busting rollers that apply an anti-adhesion aid directly to the side of the rope 120 that visually describes multiple layers of the product. A roller 155 is provided. These rollers 155 do not cause sizing or limited sizing of the rope 120. This addition of anti-adhesion aids to the sides of the rope 120, in particular to the sides showing the different layers, makes it possible for the individual pieces, in particular the more sticky layers of the individual pieces, during and / or the packing of the pieces Can help prevent it from sticking to the wrapping paper or other pieces of the product after.

  After final sizing, the multi-layered rope 120 will cut 224 individual pieces from the continuous multi-layered rope 120 and then pass to a cutting-wrapping device 144 for wrapping them in packaging material. The cutting-wrapping apparatus 144 includes a cutting device that separates individual pieces from the continuous multilayer rope 120. The cutting-wrapping device 144 also wraps the individual pieces 146. In one embodiment, the multilayer rope 120 is sufficient to be cut and the multilayer rope 120 becomes highly tacky and cut-wrapping. The cutting-wrapping device 144 includes a cooled guide wall to maintain the temperature of the multi-layered rope 120 so that it is stiff enough to prevent sticking to the device 144.

  Still further, the cutting-wrapping device 144 may include some final sizing of the piece 146.

  After the cutting and wrapping process, the individual pieces 146 in wrapped form are then packaged, which is also referred to as cartoning 226.

  In the illustrated embodiment, the finished piece 146 is packaged into a rigid package 150 using a boxing machine 151. The rigid package 150 is shown in more detail in FIG. 7 in a simplified schematic form. Rigid package 150 will include a predetermined number of rows of pieces 146, typically two rows 148, 149, arranged side by side. In the illustrated package 150, there are ten pieces in the package 150 such that each row 148, 149 includes five adjacent pieces. In order to insert the five pieces 146 into the desired row 148, 149 of the package 150, the five pieces 146 are first arranged side by side and then in the end-to-end direction, ie the final of the piece 146. It is inserted into the package 150 simultaneously with the length FL.

  Although not shown, these individual packages are then further processed, such as by being wrapped in clear plastic, then added to a larger box and then packaged for shipment to a retail store. However, these aspects and processes may be conventional and will not be discussed further.

  Although not shown in the schematic diagram of FIG. 1, the method of the present invention may utilize the recycling of available waste. For example, due to various operations, available waste may be generated that is part of any one of the confectionery compositions 102, 104 or the multi-layered rope 120 removed from the process, and this available waste If it is not reused, it will be discarded. This can occur during system maintenance intervals, startup or shutdown. There may be other opportunities where available waste may be generated.

  However, since one of the benefits of the multi-layered confectionery composition 120 is the visual appearance of the layers, the available waste needs to be dealt with much more precisely. In prior systems, the available waste could be returned to the system with limited or no effect on visual appeal. Furthermore, the reuse of available waste typically will not have a significant impact on the physical properties of the confectionery composition. However, available waste including some of the candy composition can be affected.

  Thus, some embodiments of the present invention may include reusing a portion of the multi-layer rope 120 so that the multi-layer rope 120 passes through the process of coextrusion at least twice. This available waste may be returned to various locations. Preferably, the available waste is sufficiently mixed so that the available waste can be thoroughly mixed into the individual confectionery compositions 102, 104 in order to distribute the available waste uniformly throughout the confectionery compositions 102, 104. Returning to the process of forming the confectionery compositions 102,104. Accordingly, this available waste may be returned to the processing machines 108, 111 in various embodiments of the method. Available waste as an ingredient is typically no more than 20% by weight of each confectionery composition, preferably no more than 10%, even more preferably no more than 5%, no more than 4% of the confectionery composition 102 or 104, It should be 3% or less, 2% or less, or 1% or less and / or in between. The lower the amount of available waste, the better, as the confectionery compositions 102, 104 and consequently the properties of the multi-layered rope will be more uniform and predictable.

  The available waste could be sent back to the pre-extruders 112, 113 or to the feed towers 122, 124. However, the later this available waste is added to the process, the more work that is done on that available waste to blend the available waste with the remainder of the individual confectionery composition 102, 104 components. Less, resulting in reduced uniformity of the confectionery compositions 102,104.

  Preferably, the available waste does not change visual characteristics such as color or texture, such as viscosity or elasticity, by more than 10% compared to when no available waste is added to the confectionery composition 102, 104. Preferably, it will only change by 5% or less. The effect on visual appeal could be measured by monitoring the color change using a colorimeter.

  At this point, a general overview of the processes and processing equipment used to form the multi-layered confectionery composition according to the present invention has already been described and is more specific than has been overcome or assumed by the applicants. Features and obstacles are discussed.

  Unfortunately, by using a pre-built rigid package 150, to avoid the appearance that not enough pieces are inserted into the package, or actually not enough pieces into the package. The tolerances of the individual pieces 146 need to be maintained. However, given the fact that the confectionery composition is a confectionery composition that is added together, typically formed from a plurality of different confectionery compositions having different physical properties, more specifically viscoelasticity This confectionery composition has a more complex structure. Furthermore, because these different confectionery compositions are in a layered shape, when these confectionery compositions have different physical properties, this different property, such as viscoelasticity, varies from layer to layer and is physically discontinuous. Create a lump. Thus, the different processing steps in forming a piece by processing the entire multilayer product after the entire multilayer product has been coextruded are among the confectionery compositions that form different layers of the multilayer confectionery composition. It can have different effects on different compositions. For example, a compressive force applied along the thickness T direction can cause lateral oozing of the central layer to a greater extent than the outer layer when the inner layer has a lower viscosity than the outer layer. Similarly, when passing through a cooling tunnel, one layer may cool at a faster rate than a different layer. Typically, these problems are not encountered during standard sizing and forming processes when dealing with substantially consistent confectionery compositions.

  More specifically, and with reference to FIG. 8, when using a pre-built rigid package 150, the tolerance of individual pieces 146 is that not enough pieces are inserted into the package. Need to be maintained to avoid appearance. The sum of the final widths FW of the five pieces 146 is such that the gap 152 between the end piece 146 and the side 152 of the package 150 is minimized to avoid the appearance of no piece. It is necessary not to be too small with respect to the entire package width PW of each column. Such an appearance is commensurate with what the consumer has paid for, even though a certain number of pieces (10 in this example) are actually in the package. May give a negative impression that This potential problem when the size tolerance of piece 146 is not maintained is illustrated by row 148 of package 150 in FIG.

  Similarly, tolerances for individual pieces 146 need to be maintained to avoid having too few pieces 146 actually in the package. In other words, the tolerances of the individual pieces 146 are maintained such that the sum of the final widths FW of the five pieces 146 is not sufficiently large relative to the overall package width PW of each row of that package 150. So that fewer than five pieces 146 can be inserted into the package 150. Again, this can give consumers a negative impression that they are not getting what they paid for. This potential problem associated with poor tolerances on the size of piece 146 is illustrated by column 149 of package 150 in FIG. Another issue with respect to this particular problem is that this arrangement can cause the boxing device 151 that packs the pieces into the package 150 to become clogged and cause undesired downtime for the line.

  There are two methods contemplated as the most typical way of forming the actual piece 146 from the continuous multi-layer rope 120 when using a cutting-wrapping process. These two methods are similar in operation but have significantly different effects on the potential tolerance of the final width FW dimension for individual pieces and are therefore inserted into the package 150. Affects the final tolerance of the entire row of adjacent pieces.

  In the first embodiment, referring to FIG. 9, the cutting device 168 divides the individual pieces so that the cutting line 170 is substantially aligned with the final length FL. In this configuration, the final width FW of each piece 146 is determined when dividing the piece 146 from the continuous multilayer rope 120. In another embodiment, referring to FIG. 10, cutting device 168 divides individual pieces 146 such that cutting line 170 is substantially aligned with final width FW. In this configuration, the final length FL of each piece 146 is determined when the piece 146 is cut from the continuous multilayer rope 120.

  The first cutting configuration illustrated in FIG. 9 allows for faster machining of the pieces. This is because a smaller length of the multi-layered rope 120, that is, a length corresponding to the final width FW of the piece, only needs to pass over the cutting device 168 between cuts. This can also be understood as a technical idea that fewer ropes need to be “pulled” to form individual pieces.

  Unfortunately, this configuration can result in greater variation in the critical dimension of the piece of multi-layered confectionery composition, ie, the final width FW. Since each piece side surface of the piece 146 is defined by the cutting operation, any error in the position of the cutting operation is doubled by each piece. This can be a significant disadvantage in the present application. This is because tolerances are so important and it can be difficult to control or adjust tolerances based on the complex and discontinuous nature of the multi-layered confectionery composition.

  The second cutting configuration illustrated in FIG. 10 generally provides a slower processing of the pieces relative to the first configuration. This is because a greater length of the multi-layered rope 120, ie the length corresponding to the final length FL of the piece, needs to pass over the cutting device 168 between cuts. . In other words, more of the multi-layer rope needs to be pulled during the cutting process. Thus, fewer pieces are produced if the linear velocity of the material along the flow path is the same for both processes.

  However, this second configuration provides significant advantages. In particular, by using this configuration, there is less variation in the critical dimension, ie the final width FW, from one piece to the next. This is because all of the final width FW dimensions are determined prior to severing and are substantially determined by the upstream presizer 140. Thus, when multiple pieces that are cut during this process are aligned side by side in preparation for insertion into the package 150, the sides that can be cut apart are adjacent to each other. Rather, well-maintained dimensions are placed next to each other. More specifically, the width W of this rope corresponds to the final width FW of each piece 146. This cutting method is the preferred method because it produces a much more precise final width FW.

  In one embodiment, five pieces 146 are not arranged in each row 148, 149, but seven pieces are arranged in a given row 148, 149, for a total of 14 packages 150. Piece 146. Furthermore, each piece has a desired final width FW of approximately 11 mm. Furthermore, each individual piece of wrapping paper has a thickness of approximately 0.1 mm. Therefore, the total width of the seven pieces arranged in a row so as to be adjacent to each other is approximately 78.4 mm. To avoid some of the critical problems discussed above with reference to the fact that no gaps are formed in the rows or that a full set of pieces cannot be inserted into the rows 148, 149 of the package 150. The width of the wrapped seven pieces has a tolerance range of ± 4.5 mm.

  As described above, the preferred method for forming the multilayer rope 120 is to form the multilayer rope 120 such that the width W corresponds to the final width FW of the piece 146. If this is the case, Applicants have modified the entire width of the grouped pieces prior to insertion into the rigid package 150 by various modifications or changes in the upstream process and arranged in a side-by-side configuration. It has been clarified that the width of the obtained multiple pieces can be maintained within a desired tolerance range.

  Therefore, when the average size of the final width FW of the piece 146 is out of the predetermined allowable error range, the operator may sample the final width FW of the piece 146 and adjust the processing parameter. Other parameters and processes may be monitored and implemented to provide the desired final piece 146 content and size.

  The first method for modifying and / or improving the final dimensions and dimensional tolerances of the multi-layered rope improves the consistency of the confectionery composition as it exits the co-extruder 116. About that. This consistency may be based on the compositional consistency or physical property consistency of the individual confectionery compositions 102, 104, such as but not limited to temperature and viscoelasticity.

  Typically, this compositional consistency will have a direct effect on temperature and / or viscoelasticity. As one non-inclusive example, if inadequate mixing of the powder components of the confectionery compositions 102, 104 occurs, a powder agglomerate can be extruded into its corresponding layer of the multi-layered rope 120. The layer will have elastic and viscosity properties that are significantly different from the desired or intended composition for the layer. For example, if a powder filler mass, such as calcium carbonate, is extruded into the gum layer 121 (see FIG. 5), this portion of calcium carbonate has elastic and viscosity characteristics that are significantly different from the desired gum composition. It will be. Thus, when that portion of the multi-layered rope 120 passes through the rope sizer 134, an inconsistent amount of elongation in the length L direction will occur, but more importantly, a similar consistency in the width W direction. An insignificant amount of shrinkage will also occur, creating a significant issue for downstream packaging. The amount of shrinkage in the width direction W during either the cooling or forming process (eg, in the rope sizer 134, cooling tunnel 136, presizer 140) will also be affected.

  Therefore, Applicants have found that increasing the amount of work added to this confectionery composition, especially when the confectionery composition is a gum composition, is both a compositional consistency and viscoelastic property, as well as Clarified that it may increase the consistency in temperature.

  Accordingly, the system 100 in some embodiments may include a reuse configuration, such as the reuse configuration 114, in the pre-extruder 112. This can be particularly useful when the upstream gum processing facility 108 is in the form of a batch mixer. However, the reuse may be performed at a position other than that strictly performed by the preliminary extruder. Alternatively, reuse may be performed by returning a portion of the gum composition 102 to the gum processing facility 108.

  The use of a recycling configuration allows further mixing and increases compositional consistency, which can be done when mixing large quantities of individual elements. Further, the use of the recycling configuration can act to provide improved thermal mixing of the confectionery composition 102 prior to moving downstream toward the co-extruder 116. Thus, by providing improved thermal consistency across different portions of the rope length of the first confectionery composition 102, the viscoelasticity for any given portion of the first confectionery composition 102 is: It will become more consistent and will result in a more consistent and repeatable sizing of the multi-layered rope 120. Furthermore, any relaxation present after any of the sizing steps will be more uniform as well. By providing a more consistent sizing of the multi-layered rope 120, the consistency of each piece 146 is similarly increased, improving the ability to package individual pieces 146 into a rigid package.

  A preferred amount of reuse ranges from about 25% to about 75%, but more preferably ranges from about 25% to 50%. For 25% reuse, four ropes, all having the same die surface area and the same extrusion speed, were extruded from the pre-extruder 112 and one of those ropes (FIG. 4 as an example of a return or reuse rope). ) Will be returned for further processing through the pre-extruder 112. FIG. 4 actually represents a 50% reuse configuration. In the illustration, one rope, rope 102, is allowed to pass to downstream processing equipment, while the other rope, rope 102 ', is for increased processing in the pre-extruder 112. Returned. Note that not all ropes exiting the pre-extruder 116 need have the same cross-sectional area. Typically, however, all ropes that are allowed to pass downstream for further processing are maintained at a constant surface area, while the recycle rope 102 'provides the desired amount of recycle. It may have different surface areas to provide. Thus, the three ropes could be used for 50% reuse where the combined area of the two of the ropes going downstream is equal to the area of the rope being reused.

  In FIG. 4, the return rope 102 ′ is shown being fed back to the side of the pre-extruder 112. However, the return rope 102 ′ (also referred to as “recycled rope 102 ′”) can be pre-extruded 112 via a properly configured conveyor system to provide a simpler extruder design. May be supplied back to the supply / storage tower 172.

  Applicants have also shown that sampling the amperage of the pre-extruder 112 can also provide feedback on whether there is a variation in width. More specifically, if the screw element of the extruder is maintained at a constant RPM (revolutions per minute), if the amperage used to drive the screw element changes, It provides an indication that the viscoelasticity of the material exiting the pre-extruder is not maintained at a constant or consistent value. For example, if more energy is required to extrude the same amount of product through the co-extruder 112, the product is more viscous than other products that require less energy, ie, a lower amperage. Thus, if there is a variation in the energy used to pre-extrude the various confectionery compositions 102, 104 prior to adding the confectionery compositions 102, 104 to the co-extruder 116, the confectionery compositions 102, 104 will be Variations in width W would be expected due to variations in viscoelasticity of confectionery compositions 102, 104 when coextruded. Most typically, as the amperage decreases, the corresponding width W increases, which means that the gum is less viscous and more gum is extruded through the dies of the pre-extruder 112 and the co-extruder 116. I suggest that I can. Perhaps this viscosity drop is most likely due to the higher material temperature. However, it is possible that the variation in viscoelasticity may be due to variations in the composition of the confectionery compositions 102, 104 or the completeness of the mixing.

  It is also possible to work on the confectionery compositions 102, 104 in the co-extruder itself. However, this is not very desirable.

  Thus, embodiments of the present invention increase the consistency of the final piece size by increasing the physical and compositional consistency of the confectionery composition as it is fed to the co-extruder 116. About.

  Another way to maintain the final piece size within the desired tolerance is to maintain a more consistent throughput of material through the co-extruder 116. Applicants believe that one factor affecting the throughput of confectionery compositions 102, 104 through the extruder is the feed conditions of the confectionery compositions 102, 104 to the various feed towers 122, 124 of the co-extruder 116. It was clarified that it is influenced by.

  If the co-extruder is “deficient” in one of the confectionery compositions 102, 104 of the multi-layered rope 120, a variation in width W is expected because it is extruded less than the desired amount of material. The For example, if the co-extruder is feeding the first confectionery composition 102 at a too slow rate, not enough material will be present in the layers 121, 125 of the example rope of FIG. Thus, when the multi-layer rope is exposed to subsequent downstream processing, variations in the width W dimension will be experienced. When the co-extruder is depleted of supply from one or more of the confectionery compositions 102, 104, the width W decreases, so that it may approach or pass through the lower end of the tolerance range. There will even be.

  Furthermore, if too much material is extruded by the co-extruder 116, the rope width W and thickness T (though less critical than width W), and thus the corresponding final dimensions, are typically too high. Let's go.

  This can occur because the confectionery compositions 102, 104 are too low in viscosity when the confectionery compositions 102, 104 are fed to the co-extruder 116. Presumably, when the viscosity is too low, an increase in the flow rate of the material beyond a certain dimension of the extruder die (i.e., mashrooming) occurs, so that the width W of the multilayer coextruded rope 120 and Thickness T dimensions become larger than expected so that they are not reduced to the desired dimensions by downstream sizing and processing. This therefore results in the final piece dimensions becoming too large. This is because the remainder of the forming equipment downstream of the co-extruder is not calibrated to handle the amount of material that needs to be sized to the desired final dimensions at this point.

  Alternatively, if too much material is fed into the co-extruder 116, particularly the barrel of the co-extruder 116, causing too much, the co-extruder 116 may extrude too much material. If too much material is inside the co-extrusion machine, the pressure in the co-extrusion machine 116 will typically increase, causing more than the desired amount of material to be carried through the die of the co-extrusion machine 116. Again, this results in a multi-layered rope 120 that is dimensioned such that the downstream forming equipment is not calibrated to process to the desired final width W and length L dimensions.

  Accordingly, embodiments of the present invention relate to methods and apparatus for maintaining a uniform and consistent supply of material into co-extruder 116. In one embodiment, co-extruder feed towers 122, 124 are supported on a load cell or other gravimetric device and continuously analyze the amount of product being fed to co-extruder 116. In examples where information regarding the feed rate of the material to co-extruder 116 is not available, after pre-extruder 112 and / or pre-extrusion to provide improved control of the feed rate to co-extruder 116. It is contemplated to use a loafing machine instead of the machine 112. Further, when using a loafing machine, the rate at which material is fed to the co-extruder 116 is modified without directly affecting the upstream process, such as the rate at which the product is being discharged from the pre-extruder 112.

  For example, if it is determined that too much material is being fed to the co-extruder 116 (eg, the rate at which the mass is fed to the co-extruder 116 is too great), the user may produce in the upstream of the mass. Have the opportunity to slow down the rate at which the product mass is fed to the co-extruder 116 without affecting the process. This can be done, for example, simply by increasing or decreasing the speed of the conveyor.

  The ability to increase or decrease the speed of a continuous rope may be available to some extent without affecting downstream processing, but if this is done without affecting upstream processes Due to the continuous nature of the rope, it remains to a limited extent. For example, if the user needs to reduce the speed at which the rope is being fed into the co-extruder 116, this may be due to rope jams (if the pre-extruder 112 is maintained at a constant production rate). back-up). Unfortunately, because this rope is continuous, if the pre-extruder 112 is not slowed down as well, the rope can become jammed on the rope itself, causing rope bow-tying or overlap. It can happen. However, slowing the pre-extruder can adversely affect the consistency of the physical properties of the rope, as described in more detail above. Still further, with a continuous rope, it is much more difficult to simultaneously stop feeding the feed material to the co-extruder 116. Because the rope must be cut.

  Thus, in some embodiments, it is desirable to maintain the feed rate of one or more of the confectionery compositions to the co-extruder within 10% of the desired rate, more preferably within 5% of the desired rate. Is done. The feed rate can be adjusted by shortening or lengthening the feed path between the pre-extruder or similar equipment and the co-extruder. For example, when using a continuous rope of confectionery compositions 102, 104 upstream of the co-extruder 116, the rope may be passed through a serpentine path to increase the travel distance of the rope and thereby reduce its feed rate. I can do it. Furthermore, the feed rate could be increased by manually adding a portion of the required confectionery composition 102,104. This could also be the individual chopping or addition of lumps of the required confectionery composition 102,104.

  In addition, Applicants have found that additional methods for maintaining consistent tolerances when forming a multi-layered confectionery composition include a plurality of different confectionery compositions at least during a bulk sizing operation. It was clarified that it included maintaining viscoelasticity of the same level between them. More specifically, it is desirable to have an elastic ratio of 3: 1 or less between any given pair of confectionery compositions in the multilayer confectionery composition. However, it is more preferred that this ratio is 2.5: 1 or less, even more preferably 2: 1 or less. By pairing the elasticity of different confectionery compositions, various sizing processes such as bulk sizing or pre-sizing can be more precisely controlled. This is because the multi-layered rope 120 is more closely approximated by a rope formed from a continuous material. In other words, matching viscoelasticity facilitates different confectionery compositions to flow together during various processes that cause dimensional deformation of the multi-layered rope 120.

  Preferably, the viscosity of a given layer is 90% or more, preferably 95% or more of the viscosity of other layers and especially adjacent layers. However, at a minimum, the viscosity of one layer relative to another layer is 80, 81, 82, 83, 84, 85, 86, 87, 89, 90, 91, 92, 93, 94 or 95% and / or It may be a range between. These values may be those immediately before the coextrusion or bulk sizing step or both steps. Again, recycling portions of the confectionery compositions 102, 104 can be used to maintain the desired viscosity match between the different confectionery compositions.

  Compensation may be included to correct this deficiency when the viscoelasticity is not perfectly consistent between the different layers of the multi-layered confectionery composition. For example, and referring to FIG. 5, if layers 121 and 125 have a higher viscosity value than intermediate layer 123, this intermediate layer will be the other two layers when extruded so that the final dimensions are the same. 121, 125 may have slightly different dimensions. For example, if the top and bottom layers 121 and 125 are extruded with a width W of approximately 30 mm, this intermediate layer has a lower viscosity and is likely to ooze out, so it is extruded with a width of less than 30 mm. Also good. At that time, during the sizing of the downstream multi-layered rope, even if any compression is applied to the intermediate layer 123 to cause some lateral oozing, the intermediate layer will remain at the edge 174, It will not spread outward from 176 laterally. Lateral oozing beyond the edges 174, 176 will again affect the desired final width FW of a given piece 146.

  Preferably, when this compensation is used, the width of adjacent layers 121, 123, 125 is less than before the bulk sizing step and even less than after the pre-sizing 220 step. With a first percentage difference after sizing 214. Preferably, after bulk sizing, the percentage difference between adjacent layers is 5% or less, and even more preferably, the percentage difference after bulk sizing is 0.5% or less.

  The additional benefit of co-extrusion of multiple confectionery compositions into one multi-layered confectionery will now be discussed. If one of the confectionery compositions typically has ingredients that can be degraded or lost by the usual processing steps to form that type of confectionery composition, those ingredients May be added to other confectionery compositions so that they do not need to be exposed to a process that forms part of the overall multilayer confectionery composition but is more harmful.

  For example, the formation of a gum composition typically includes at least some level of high shear and / or high temperature mixing. However, some ingredients such as fragrances, sensates, and sweeteners (especially encapsulated sweeteners) can be very sensitive to high shear and / or high temperatures. By using a second confectionery composition, these very sensitive ingredients can be processed in a high shear and / or high temperature process while these highly sensitive ingredients are still available to consumers. May be added to the second confectionery composition so that it is not exposed to. This second confectionery composition thus acts as a carrier for these very sensitive ingredients.

  In addition, some of these ingredients, such as encapsulated sweeteners, are intended to delay the release of the effects of the ingredients as the user continues to chew the product, such as when used in gums. Has been. In some examples, when these ingredients are added to a confectionery formed solely from the second confectionery composition, the desired effect that the ingredients are intended to be eaten too quickly to give them. Will not be realized. However, by pairing the second confectionery composition with a first confectionery composition, such as a gum composition, the user chews the multi-layer confectionery composition, so that of these longer lasting ingredients Some will be absorbed and combined with the long lasting gum composition, thus preventing the ingredients from being eaten by the user. In this case, the first confectionery composition may be a carrier for these components. This is because these ingredients are present in the consumer's mouth during the long-term chewing experience provided by including the first confectionery composition as a gum composition.

  Rather than worrying about the processing sensitivity of the various ingredients, the manufacture of a multi-layered confectionery composition can provide additional benefits that would not be possible by providing one type of confectionery composition. A savory or sensory profile can be provided. For example, it is often desirable for a gum composition to give consumers a very strong initial sensory and flavor blow so that they can be enjoyed almost immediately. However, the inclusion of gum base elements, particularly water-insoluble elastomeric elements, in the gum may completely cover these ingredients and inhibit or delay the release of these ingredients from the composition. Sense will be delayed or more of these ingredients will need to be included in the formulation for the gum composition. However, if these ingredients are being carried in a water soluble second confectionery composition such as a chewy candy, using the same amount of that ingredient can improve the user experience. Intended. Alternatively, a similar level of that initial sensation can be brought to the consumer by providing less of that component.

  Another feature that may facilitate improved tolerance is adhesion between adjacent layers of the multi-layered confectionery composition. By having a strong bond between adjacent layers, transverse strain in the multi-layered rope due to linear stretching during the forming process is transmitted more consistently from layer to layer.

  This is particularly beneficial when performing bulk sizing and presizing of the multi-layered rope 120 using a rope sizer. Rope sizers tend to operate based on stretching the multi-layered rope 120 so that if there is not enough adhesion between adjacent layers, the outer layers, eg, layers 121 and 125, are Let's slip. When the outer layers 121 and 125 slide with respect to the intermediate layer 123, the reduced force acts on the intermediate layer 123, reducing the effectiveness of the sizing action on the intermediate layer 123. Accordingly, a significantly less uniform sizing of the intermediate layer 123 will occur, resulting in a poorly formed rope.

  Therefore, in some embodiments of the present invention, the resulting multi-layered confectionery composition is such that the individual layers 121, 123, 125 cannot be separated from each other without breaking the individual layers. , Have sufficient adhesion. In other words, if one tries to pull the layers apart, the individual layer pieces will break and remain adhered to the other layers rather than separated from the other layers.

  However, this level of adhesion is not necessary. What is needed is that adjacent layers be subjected to various sizing operations required to reduce the size of the multi-layered rope 120 from its extruded size to its final size prior to the cutting process. There is only sufficient adhesion between adjacent layers so that they do not slip relative to each other.

  When one of the confectionery compositions is a candy composition, it is desired that the candy composition is substantially or completely granulated (ie crystallized) prior to packaging. A high level of granulation reduces the cold flow of the candy composition after packaging. Due to the cold flow after packaging, particularly in the package 150 as illustrated in FIG. 7, adjacent pieces are shaped together, which makes it difficult to remove the pieces from the package. It also gives a negative impression to consumers.

  In some embodiments, it is desirable that the candy composition be substantially crystallized prior to co-extrusion, after conditioning, or at least prior to bulk sizing. In these situations, prior to coextrusion, conditioning or bulk sizing, the candy composition is at least 85% crystallized, more preferably at least 90% crystallized, more preferably at least 95% crystallized. Preferably even at least 97.5% crystallized.

  Further, avoiding cold flow will also prevent individual layers from causing changes in the dimensions of the multi-layered rope 120 except during the desired bulk and pre-sizing steps.

  Note that individual pieces of processing equipment, such as pre-extruder 112, can be used to feed downstream parallel equipment. For example, two pre-extruded ropes can be produced by a pre-extruder 112 for feeding to two separate but parallel co-extruders. Similarly, when two ropes are produced by one pre-extruder, the two ropes could be preconditioned by passing them through the same preconditioner 118.

  In some embodiments, the plurality of pieces 146 may be contained in a single bag or container in an unwrapped state. Thus, each individual piece will make surface contact with the other piece. However, because the gum composition 102 and the candy composition 104 (when used) can be very sticky, contact between them can cause the pieces 146 to stick together. . This is especially true when the candy composition is used as one of those layers. Accordingly, the present invention relates to a method for reducing the tendency of pieces to contact and stick together. With reference to FIGS. 11 and 12, a further piece shape is illustrated to attempt to prevent this sticking together.

  In FIG. 11, each individual piece has a substantially rectangular layer 121, 123, 125. However, the intermediate layer 123 has a length and / or width that is less than the length and / or width of the outer layers 121, 125, so that the intermediate layer 123 (also referred to as the inner layer 121) It is more difficult to contact the surface. In order for the outer surface of layer 123 to come into contact with another piece 146, the corners of the other piece must pass into the recess formed between the outer layers 121,125. Thus, if the corner contacts the inner layer 123, only line contact, or perhaps only point contact, is formed between them, reducing the adhesion between the two pieces.

  FIG. 12 illustrates a further piece shape. In FIG. 12, piece 146 has top and bottom layers 121, 125 with curved top and bottom surfaces 174, 176, respectively. Further, the layer 123 may or may not have a recessed side 178. However, even in the case of a flat side 178, if the flat side 178 comes into contact with the top or bottom sides 174, 176, only line contact is formed between them, not surface-to-surface contact. The adhesion is further reduced.

  FIG. 13 illustrates a further piece shape. In FIG. 13, piece 146 has top and bottom layers 121, 125 having top and bottom curved surfaces 174, 176 facing away from each other. This configuration incorporates the advantages of the piece illustrated in FIG. Further, the intermediate layer 123 has a width and / or length that is less than the width and / or length of the outer layers 121, 125, so that the intermediate layer 123 provides the benefits discussed with respect to piece 146 of FIG. It is recessed inward in the lateral direction. However, in this embodiment, layer 123 has side surfaces 180, 182 that are also curved. These curved sides 180, 182 further facilitate contact between adjacent pieces because they are line contacts rather than surface-to-surface contacts.

  Since typically one dimension is defined by the cutting process, typically only the length or width of the intermediate layer will be less than the length or width of the outer layer. However, it is contemplated that in an optimal configuration both the length and width are recessed.

Specific Process Examples So far, a general overview of processing methods and corresponding equipment and the difficulties and features associated with them when processing multi-layered confectionery compositions has been discussed, so that more of process and processing parameters Specific examples are discussed.

  Examples are described with reference to FIGS. 1A, 1B, 3, 5 and 6. FIG. The resulting multi-layered confectionery composition comprises three layers 121, 123 having an uppermost layer and a lowermost layer 121, 125 formed from a single gum composition 102 and an intermediate layer 123 formed from a chewy candy composition 104. , 125. Furthermore, all three layers 121, 123, 125 define a part of the outer periphery of the cross-section of the multilayer confectionery composition, in particular at least two sides.

Gum Processing Processing of the gum composition is accomplished by melting the gum base to a temperature of about 75 ° C. to about 95 ° C. in a batch mixer 108 ′, but most typically in a separate mixer. Will start. The batch mixer 108 'will be preheated to a temperature of about 40 ° C to 55 ° C. Next, the powder ingredients, including sweeteners or powder colorants, are added to the batch mixer 108 'and mixed. After these powders are mixed, the molten gum base will be added in combination with the melted fat and liquid sweetener. After mixing for some time, the fragrance is added. During stirring, the temperature of the mixture should remain between the 40 ° C. and 55 ° C. ranges indicated above. After blending powder sweetener, colorant, gum base, fat, liquid sweetener and fragrance for a predetermined period of time, based on the desired consistency and texture, further long lasting fragrance and sweetener in a batch mixer 108 '. After further mixing, the gum composition 102 is finished and ready to be pre-extruded.

  Typically, the gum composition 102 will be allowed to stand for approximately 5-20 minutes prior to being added to the pre-extruder 112, but more than one and a half hours before being added to the pre-extruder 112. It is not allowed to stand still.

Candy Processing While the gum composition is being processed, a candy composition (also referred to as a “chew candy composition”) is being processed.

  Processing of the candy composition will begin by forming a fondant batch. This fondant is disclosed in Japanese Patent Application Publication No. 2007-215450, Patent Application No. 2006-37910, filed on February 15, 2006 and published on August 30, 2007, which is incorporated herein by reference in its entirety. It is preferably formed using the processing steps specified in the specification. This processing would involve using a fondant manufacturing device with a steam jacket at a pressure of about 0.5-2.5 bar and capable of cooling to about 30-60 ° C. with water.

  A mixture of powder and syrup-based sweeteners and water are mixed in this processor. The syrup formed from these various sweeteners and water is stirred at a rate of about 10 RPM to 20 RPM and then cooked using low pressure steam. The syrup is cooked until a temperature of about 110 ° C. to 150 ° C. is reached. The steam is then stopped and cooling water is introduced into the jacket of the processing machine. The stirrer speed is increased to about 25 RPM to 75 RPM. The syrup is then cooled to approximately 45 ° C. to 65 ° C., resulting in a finely crystallized fondant having an average particle size of about 25 microns to 40 microns. The fondant is then discharged into a plastic holding container.

  A candy composition using this fondant as an ingredient is then formed. This candy cooking device is preferably a semi-continuous candy cooking device. First, a master batch of syrup containing liquid and powder sweeteners and water is mixed. The masterbatch is heated and maintained at a temperature of about 40 ° C. to 70 ° C. in a holding tank heated using low pressure steam. Oil, emulsifier, and liquid fat are added to the holding tank.

  Next, a masterbatch containing oil, emulsifier, and liquid fat is preheated to a temperature of about 85 ° C to 115 ° C. Color is then added.

  The masterbatch then applies medium pressure steam at a pressure of about 1.5 bar to 3.5 bar until a final cooking temperature of about 120 ° C to 145 ° C is obtained to form a cooked candy lump. It is added to the final cooker that was heated using.

  The cooked candy mass is then added to the candy bowl and then a vacuum of about 2.5 to 6.5 inches (about 6.35 cm to about 16.3 cm) Hg is applied. Gelatin is then added to this cooked candy mass in the candy bowl and mixed well and gelatinized cooked candy mass ("gelatinized" as used herein is It simply means that gelatin has been added to the mass).

  The gelatinized cooked candy lump is then dropped onto a cooling table that is cooled to about 5 ° C. to 25 ° C. by circulating water. Next, acid and fragrance were added to the gelatinized cooked candy mass by folding until the temperature of the mixture dropped to about 45 ° C. to 80 ° C. and folded. A gelatinized candy mass is formed.

  This folded gelatinized candy mass is then transferred to a kneader. The stand of this kneader is also cooled to about 5 ° C. to 25 ° C. by circulating water. The candy is kneaded for several cycles until the temperature drops to about 35 ° C to 65 ° C.

  The previously prepared fondant is then added to the folded gelatinized candy mass to form a chewy candy composition. Typically, fondant will be approximately about 5% to 20% by weight of the total mass of the chewy candy composition. When mixed with the folded gelatinized candy mass, the fondant itself can no longer be distinguished within the chewy candy composition. Thus, after the fondant is added and the fondant is uniformly mixed with the folded gelatinized candy mass, the combined mass is considered to be a candy, not a fondant. This chewy candy composition is then transferred to a double arm pulling machine where it is first processed in a slow cycle and then in a fast cycle to form a chewy candy composition 104. The candy composition will have a temperature of about 30 ° C to 50 ° C when finished drawing.

Formation / Packaging After the two confectionery compositions 102, 104 (gum composition and chewy candy composition) are manufactured, the confectionery compositions 102, 104 are formed into a multi-layered confectionery composition.

  The gum composition 102 is first pre-extruded 206 using a pre-extruder 112. The pre-extruder 112 has a recycle rate of about 25% to 50% to maintain at least one rope that is allowed to pass to downstream processes and gum temperature, composition and viscoelastic uniformity. And at least one rope returned for. The barrel of the pre-extruder is maintained at a temperature of about 35 ° C. to 50 ° C., while the nozzle or die of the extruder has a temperature of the gum composition 102 exiting the pre-extruder 112 of about 45 ° C. It is maintained at a temperature between 45 ° C. and 60 ° C. so that it is 65 ° C.

  The gum composition 102 is then preconditioned 212 in preconditioning tower 118 at about 15 ° C. to 35 ° C. and exits at a temperature of about 35 ° C. to 50 ° C. after a sufficient number of passes. Having a relative humidity of about 20% to 45%.

  The candy composition 104 is passed through the preliminary extruder 113.

  The ropes of gum composition 102 and candy composition 104 are then fed to co-extruder 116 and co-extruded 208. The co-extruder gum extruder is maintained at about 45 ° C to 60 ° C, while the co-extruder candy extruder is maintained at about 30 ° C to 45 ° C. The gum composition 102 and the candy composition 104 are extruded through an extruder die to form three ropes having a width W dimension of about 24 mm to 35 mm and a thickness T of about 18 mm to 27 mm, thus each layer 121, 123, 125 has a thickness T of about 6 mm to 9 mm.

  Preferably, the weight ratio of gum to candy is maintained from about 2.5: 1 to 3.5: 1. This ratio is maintained as a function of extruder speed. Thus, the individual extruder parts of the co-extruder are driven independently so that the proportions of candy and gum composition can be adjusted independently.

  After coextrusion, the resulting multi-layered rope 120 is bulk-sized 214 using a rope sizer 134 in the presence of an anti-stick processing aid 143 in the form of mineral oil. The multilayer rope 120 is reduced from a width W of about 30 mm and a thickness of about 24 mm to a size having a width W of about 10 to 15 mm and a thickness T of about 5 to 8 mm.

  The multi-layer rope 120 is then maintained at about 2 ° C. to 15 ° C. and about 25% to 50% relative humidity such that the multi-layer rope 120 exits the conditioner 136 at a temperature of about 20 ° C. to 40 ° C. Conditioned 218 in conditioner 136.

  The conditioned multi-layered rope 120 is then presized 220 to approximately its final dimensions with the presizer 140 in the presence of the anti-stick processing aid 149. This multi-layered rope is preferably sized to a thickness T of about 5 to 6 mm and a width W of about 10.5 to 11.5 mm.

  The multi-layered rope 120 is then wrapped by a cutting and wrapping device 144 to a final length FL of about 35 mm, a final width FW of about 11 mm and a final thickness FT of about 5.5 mm. Are cut and wrapped 224 into individual pieces 146 having an average size of In some embodiments, samples of individual pieces 146 are inspected. During sampling, the sample dimensions are measured to determine the average size of the individual pieces. When the average size is outside the predetermined tolerance range, various processing parameters are adjusted so that the individual pieces fall within the size tolerance range. For example, the duration of mixing in the pre-extruder and / or co-extruder may be lengthened or shortened. Furthermore, the amount of the one or more confectionery compositions fed to the co-extruder can be adjusted, or the viscosity of the one or more confectionery compositions can be adjusted.

  Finally, the individually wrapped pieces 146 are grouped into a side-by-side arrangement of seven pieces and then packed 226 into a package 150 within the packing device 151.

  All references, including publications, patent applications, and patents, cited in the present specification are shown to be incorporated herein by reference, individually and expressly, in their entirety. It is incorporated herein by reference to the same extent as described in the specification.

  The terms “one (a)” and “an” and “the,” said “the” and similar directives relating to describing the present invention (especially with regard to the appended claims) The use of is to be construed to include both the singular and the plural unless specifically stated otherwise herein or otherwise clearly contradicted by context. The terms “comprising”, “(having)” (“including”, and “containing”) are open-ended terms (unless otherwise noted) That is, it should be construed as meaning “including but not limited to.” The description of the range of values in the present specification falls within the range unless otherwise specified in the present specification. It is only intended to serve as a concise notation for individually referring to each separate value, as if each separate value was individually described herein. Each separate value is incorporated herein, and all methods described herein are expressly in conflict with the context or unless otherwise indicated herein. Unless otherwise noted, any suitable order may be implemented, and any and all examples, or the use of illustrative words (eg, “... Etc.”) presented herein may be used in accordance with the present invention. It is intended only to facilitate an understanding of the invention and is not intended to limit the scope of the invention, unless expressly claimed otherwise, as defined in the claims. None of the missing elements should be construed as indicating essential to the practice of the invention.

  Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations on those preferred embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors anticipate that those skilled in the art will appropriately employ such variations, and that the inventors have practiced the invention in a manner different from that specifically set forth herein. Is intended to be. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Furthermore, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims (17)

A method of forming a multi-layer confectionery composition comprising:
Providing a co-extruder having at least a first supply port and a second supply port;
A continuous multi-layer rope comprising at least one layer of a first confectionery composition and at least one layer of a second confectionery composition that differs from the first confectionery composition in at least one aspect. Co-extruding the first confectionery composition with the second confectionery composition from the co-extruder to form,
Sizing the multilayer rope;
Separating the multilayer rope into pieces,
The co-extrusion includes extruding a multi-layered rope having three successive layers;
The first confectionery composition is extruded as a first layer and a third layer;
The second confectionery composition is extruded as a second layer;
The second layer is sandwiched between the first layer and the third layer;
When the multilayer rope exits the co-extruder, the first layer and the third layer are completely separated from each other;
The first confectionery composition extruded as the first layer and the third layer is supplied to the co-extruder through the first supply port and is extruded as the second layer. A method wherein a confectionery composition is fed to the co-extruder via the second feed port.   The method of claim 1, further comprising pre-extruding the first confectionery composition prior to the step of co-extrusion.   The method of claim 1 or 2, further comprising post-conditioning the multilayered rope after the step of co-extruding the first confectionery composition with the second confectionery composition. The step of sizing the multilayer rope includes extending the rope by rope sizing, wherein the rope sizing includes a plurality of continuous reverse rotations acting on opposite top and bottom surfaces of the multilayer rope. Passing the multi-layered rope through a pair of rollers that the stretching of the rope increases the linear velocity of the multi-layered rope in each pair of counter-rotating rollers;
Stretching the multi-layered rope stretches the rope linearly along its length, reducing the thickness and width of the rope, the thickness and width during the step of rope sizing the rope. Perpendicular to the length and direction of travel, wherein the rope sizing is performed by a plurality of consecutive counter-rotating roller pairs, where continuous when moving along the path defined by the rope 4. A method according to any one of claims 1 to 3, wherein a typical roller pair is reduced in size.   The method further comprises homogenizing the first confectionery composition comprising pre-extruding the first confectionery composition prior to the co-extruding step, wherein the pre-extruding step is a part to be reused. 5. A method according to any one of claims 1 to 4, comprising recycling a portion of the pre-extruded confectionery composition such that is pre-extruded at least twice.   After the co-extrusion step, the multilayer rope has a width and a thickness, both the width and thickness being substantially perpendicular to each other and the length of the rope, the width and the thickness 6. A method according to any one of the preceding claims, wherein both are greater than the desired final width and the desired final thickness. The co-extruding step comprises co-extruding a multilayer confectionery composition such that the second confectionery composition has a lower viscosity than the first confectionery composition;
The continuous multi-layer rope has an initial width and initial thickness greater than two dimensions of the final piece of the multi-layer confectionery composition;
The sizing step includes extending the multilayer rope along a flow path of the multilayer rope and contracting both a width and a thickness of the multilayer rope. The method according to any one of claims 1 to 6, comprising bulk sizing.   When the multi-layer rope exits the co-extruder, the first layer, the second layer, and the third layer each form a portion of the outer periphery of the cross-section of the multi-layer rope at the end of the multi-layer rope. 8. A method according to any one of the preceding claims, wherein the method is defined. The step of sizing includes bulk sizing the multilayer rope;
9. A method according to any one of the preceding claims, wherein the temperature of the first confectionery composition immediately prior to the step of bulk sizing the multilayered rope is a substantially uniform temperature.   The first confectionery composition has a first temperature just before the co-extrusion step, the second confectionery composition has a second temperature just before the co-extrusion step; The temperature difference between the first temperature and the second temperature is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 10. A method according to any one of claims 1 to 9, wherein the method is below 17, 18, 19, or 20 ° C. The step of separating comprises dividing the multi-layered rope into individual pieces;
Said first viscosity of the first confectionery composition, wherein the multi-layered rope prior to the step of co-extrusion coincides with the second viscosity of the second confectionery composition, of claims 1 to 6 The method according to any one of the above.   A step of pre-extruding the first confectionery composition prior to the step of co-extruding the multilayered rope to give the first confectionery composition a first viscosity within a desired viscosity range. The method of claim 11, further comprising: Producing the first confectionery composition comprising mixing a plurality of ingredients in at least one first mixer to produce the first confectionery composition;
Producing the second confectionery composition comprising mixing a plurality of ingredients in at least one second mixer to produce the second confectionery composition;
The method according to any one of claims 1 to 12, further comprising:   The method according to any one of claims 1 to 13, wherein the first confectionery composition is a gum composition and the second confectionery composition is a candy composition. Further comprising applying an anti-adhesion processing aid to the multilayer rope;
The sizing step is performed after applying the adhesion preventing processing aid,
15. The process of claim 1, wherein applying the anti-adhesion processing aid weakens the visual distinction between the first layer, the second layer, and the third layer by 10% or less. The method according to claim 1.   The method according to any one of claims 1 to 15, wherein the second confectionery composition is a candy composition.   17. The method of any preceding claim, further comprising forming the multi-layered rope to have at least one curved surface such that the individual pieces have at least one curved surface. The method according to item.

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